Abstract: A reactor module for Fischer-Tropsch synthesis having a generally rectangular reactor block with a stack of plates defining flow channels for coolant and flow channels for the synthesis reaction arranged alternately in the block. The synthesis flow channels extend in a generally vertical direction between upper and lower faces of the reactor block and are defined by plates in combination with either bars or sheets such that each channel is of width no more than 200 mm. The coolant flow channels are oriented in the same direction, and communicate through distributor chambers with inlet and outlet ports at side faces of the reactor block. A plant may contain a multiplicity of such reactor modules operating in parallel, the modules being interchangeable and replaceable. The temperature control is enhanced by allowing the coolant flow to be parallel to the synthesis gas flow.

Abstract: A plant is provided for processing natural gas. The plant comprises two or more modules connected in parallel. The plant is configured to convert the associated gas into a material with a higher density. In addition, a method of processing gas associated with one or more oil wells. The method comprises the steps of: providing a modular plant comprising two or more modules in parallel wherein at least one of the modules is a robust module and at least one of the modules is an economical module; turning down one or more of the modules when productivity drops; switching off one or more of the modules at least when productivity drops beyond the turndown limit. The natural gas is treated in a Fischer-Tropsch unit.

Abstract: A compact catalytic reactor for Fischer-Tropsch synthesis (50) comprises a reactor module (70) defining a multiplicity of first and second flow channels arranged alternately, for carrying a gas mixture, and a coolant respectively. A removable gas-permeable catalyst structure (82) with a substrate for example of metal foil is provided in each flow channel in which the synthesis reaction is to occur. The reactor module (70) is enclosed within a pressure vessel (90), the pressure within the pressure vessel being arranged to be at a pressure substantially that of the high pressure reacting gas mixture. Consequently all the flow channels within the module are either at the pressure of their surroundings, or are under compression; no parts are under tension. This simplifies the design of the module, and increases the proportion of reactor volume which can be occupied by the catalyst.

Abstract: A catalytic reactor comprises a plurality of fluid-impermeable plates defining side-by-side flow channels between them. Tight fitting within each flow channel is a sheet of corrugated material whose surfaces are coated with catalytic material. At each end of the flow channels there may be headers for supply gas mixtures to the flow channels, the headers communicating with adjacent channels being separate. The reactor enables different gas mixtures to be supplied to adjacent channels, which may be at different pressures, and the corresponding chemical reactions are also different. Where one of the reactions is endothermic while the other reaction is exothermic, heat is transferred through the wall of the tube separating the adjacent channels, from the exothermic reaction to the endothermic reaction. The provision of side=by-side flow channels provides for structural strength and for enhanced heat transfer.

Abstract: A method for causing chemical reactions between fluids, comprising the steps of arranging a plurality of metal sheets for providing first fluid flow channels adjacent to and in heat transfer contact with second fluid flow channels between adjacent ones of the metal sheets, placing catalyst material within at least some of the flow channels, passing a first fluid mixture through the first fluid flow channels and a second fluid mixture through the second fluid flow channels, wherein the first fluid mixture is different from the second fluid mixture, each fluid mixture undergoing separate reactions, one of the reactions being endothermic while the other reaction is exothermic, and causing heat to transfer between the adjacent fluid flow channels.

Abstract: A process for converting methane to higher molecular weight hydrocarbons comprises: (A) reforming methane by catalytic reaction with steam at elevated temperature to generate carbon monoxide and hydrogen; (B) subjecting the mixture of carbon monoxide and hydrogen to a Fischer-Tropsch reaction to generate one or more higher molecular weight hydrocarbons and water; and C) extracting or removing one or more oxygenates from the water. The oxygenates are either or both: on start-up of the process, catalytically combusted to provide heat for step (A), and replaced at least in part with methane from tail gas from step (B) when the temperature attains or exceeds the combustion temperature of methane; and/or used as a fuel-enhancer for tail gas from step (B) for steady-state heat provision in step (A).

Abstract: A compact catalytic reactor (20) for reforming comprises a reactor module (70) to define a multiplicity of first and second flow channels arranged alternately, for carrying first and second gas flows, and a removable gas-permeable catalyst structure (80) with a substrate for example of metal foil is provided in each flow channel in which a chemical reaction is to occur. The reactor is for use with a first gas flow whose pressure is above ambient pressure and is no less than that of the second gas flow. The reactor module (70) may be formed of a stack of plates (72, 74, 75). The module (70) is enclosed within a pressure vessel (90), the pressure within the pressure vessel being arranged to be at a pressure substantially that of the first gas flow. Consequently no parts of the module (70) are under tension. This simplifies the design of the reactor module, and increases the proportion of its volume occupied by the catalyst.

Abstract: A method for causing chemical reactions between fluids, comprising the steps of arranging a plurality of metal sheets for providing first fluid flow channels adjacent to and in heat transfer contact with second fluid flow channels between adjacent ones of the metal sheets, placing catalyst material within at least some of the flow channels, passing a first fluid mixture through the first fluid flow channels and a second fluid mixture through the second fluid flow channels, wherein the first fluid mixture is different from the second fluid mixture, each fluid mixture undergoing separate reactions, one of the reactions being endothermic while the other reaction is exothermic, and causing heat to transfer between the adjacent fluid flow channels.

Abstract: A compact catalytic reactor for Fischer-Tropsch synthesis (50) comprises a reactor module (70) defining a multiplicity of first and second flow channels arranged alternately, for carrying a gas mixture, and a coolant respectively. A removable gas-permeable catalyst structure (82) with a substrate for example of metal foil is provided in each flow channel in which the synthesis reaction is to occur. The reactor module (70) is enclosed within a pressure vessel (90), the pressure within the pressure vessel being arranged to be at a pressure substantially that of the high pressure reacting gas mixture. Consequently all the flow channels within the module are either at the pressure of their surroundings, or are under compression; no parts are under tension. This simplifies the design of the module, and increases the proportion of reactor volume which can be occupied by the catalyst.

Abstract: Methane is reacted with steam, to generate carbon monoxide and hydrogen in a first catalytic reactor (14); the resulting gas mixture can then be used to perform Fisher-Tropsch synthesis in a second catalytic reactor (26). In performing the steam/methane reforming, the gas mixture is passed through a narrow channel in which the mean temperature and exit temperature are both in the ranges 750° C. to 900° C. the residence time being less than 0.5 second, and the channel containing a catalyst, so that only those reactions that have comparatively rapid kinetics will occur. The heat is provided by combustion of methane in adjacent channels (17). The ratio of steam to methane should preferably be 1.4 to 1.6, for example about 1.5. Almost all the methane will undergo the reforming reaction, almost entirely forming carbon monoxide. After performing Fischer-Tropsch synthesis, the remaining hydrogen is preferably fed back (34) to the combustion channels (17).

Abstract: A catalyst support is made by coating a metal substrate with a solution containing a precursor for a ceramic and an amphiphilic compound, and treating the coating such that it forms a micelle structure. The coating is then treated to form a mesoporous ceramic coating on the metal substrate. The micelle structure acts as a template, so that the pores are of regular size. The active catalytic material can then be deposited in the pores. The metal substrate may for example be a corrugated foil, which can enable reaction heat to be dissipated from hot spots.

Abstract: A compact catalytic reactor (10) for performing a chemical reaction between reactants defines a multiplicity of first and second flow channels (16, 17) arranged alternately, the first flow channels providing flow paths for reactants and the second flow channels providing a source of heat for the reaction. Each flow channel in which a chemical reaction is to take place contains a removable fluid-permeable catalyst structure (20). The walls defining the first flow channels (16), and preferably those of the second flow channels (17) too, are treated so as to have surfaces with a high emissivity. This reactor is particularly suited to reactions carried out at a temperature above about 500° C., at which temperature radiative heat transfer becomes significant.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately in the reactor, for carrying first and second fluids, respectively, wherein at least the first fluids undergo a chemical reaction. Each first flow channel containing a removable gas-permeable catalyst structure (20) incorporating a metal substrate, the catalyst structure defining flow paths therethrough, with catalytic material on at least some surfaces of each such path. The catalyst structure also incorporates a multiplicity of projecting resilient lugs (22) which support the catalyst structure (20) spaced away from at least one adjacent wall of the channel (17).

Abstract: A catalytic reactor comprises a plurality of fluid-impermeable plates defining side-by-side flow channels between them. Tight fitting within each flow channel is a sheet of corrugated material whose surfaces are coated with catalytic material. At each end of the flow channels there may be headers for supply gas mixtures to the flow channels, the headers communicating with adjacent channels being separate. The reactor enables different gas mixtures to be supplied to adjacent channels, which may be at different pressures, and the corresponding chemical reactions are also different. Where one of the reactions is endothermic while the other reaction is exothermic, heat is transferred through the wall of the tube separating the adjacent channels, from the exothermic reaction to the endothermic reaction. The provision of side=by-side flow channels provides for structural strength and for enhanced heat transfer.

Abstract: Natural gas is reacted with steam for generating carbon monoxide and hydrogen in a first catalytic reactor. The resulting gas mixture is used to perform Fischer-Tropsch synthesis in a second catalytic reactor. After performing Fischer-Tropsch synthesis, the remaining hydrogen is separated from a hydrocarbon-rich stream using a hydrogen-permeable membrane, and the hydrocarbon-rich stream is returned to be subjected to steam reforming. Preferable, the hydrogen-rich stream is supplied to a combustion channel for providing heat for the endothermic steam-reforming reaction. The overall process converts natural gas to longer-chain hydrocarbons and can provide a carbon conversion of more than 80%.

Abstract: A catalytic reactor comprises a plurality of fluid-impermeable plates defining flow channels between them. Tight fitting within each flow channel is a sheet of corrugated material whose surfaces are coated with catalytic material. At each end of the flow channels are headers to supply gas mixtures to the flow channels, the headers communicating with adjacent channels being separate. The reactor enables different gas mixtures to be supplied to adjacent channels, which may be at different pressures, and the corresponding chemical reactions are also different. Where one of the reactions is endothermic while the other reaction is exothermic, heat is transferred through the wall of the tube separating the adjacent channels, from the exothermic reaction to the endothermic reaction.

Abstract: A compact catalytic reactor defines a multiplicity of first and second flow channels arranged alternately, the first flow channels being no more than 10 mm deep and providing flow paths for combustible reactants, and containing a catalyst structure (20) to catalyse combustion of the reactants, and having at least one inlet for at least one of the reactants. The first flow channel also includes an insert (40 or 60) adjacent to each inlet, this insert not being catalytic to the combustion reaction; the insert may define gaps which are narrower than the maximum gap size for preventing flame propagation.

Abstract: A process for converting methane to higher molecular weight hydrocarbons comprises (A) reforming methane by catalytic reaction with steam at elevated temperature to generate carbon monoxide and hydrogen; (B) subjecting the mixture of carbon monoxide and hydrogen to a Fischer-Tropsch reaction to generate one or more higher molecular weight hydrocarbons and water; and (C) extracting or removing one or more oxygenates from the water. The oxygenates are either or both: on start-up of the process, catalytically combusted to provide heat for step (A), and replaced at least in part with methane from tail gas from step (B) when the temperature attains or exceeds the combustion temperature of methane; and/or used as a fuel-enhancer for tail gas from step (B) for steady-state heat provision in step (A).

Abstract: A valve assembly (10) comprises a vortex chamber (14) with an axial outlet port (20), a main inlet port (16) for a fluid to be controlled, and a substantially tangential inlet port (25); the fluid enters through an inlet chamber (13) in which is a mechanical valve (26) movable so as to obstruct fluid flow into the vortex chamber (14). A duct (24) links the inlet chamber (13) to the tangential inlet port (25) of the vortex chamber. The position of the mechanical valve (26) affects the flow of fluid through the duct (24), so the vortex chamber (14) amplifies the effect of the mechanical valve. Further movement of the valve (26) closes off flow altogether (40). The assembly may include a weir (36) in the outlet, to separate gas and liquid phases.

Abstract: A compact catalytic reactor comprises a stack of plates (72, 74, 75) to define a multiplicity of first and second flow channels arranged alternately in the stack; each flow channel in which a chemical reaction is to take place is defined by straight-through channels across at least one plate, each such straight-through channel containing a removable gas-permeable catalyst structure (80) incorporating a metal substrate. The first flow channels (76) are oriented in a direction that is perpendicular to that of the second flow channels (77), and between successive second flow channels in the stack the reactor defines at least three side-by-side first flow channels (76); and the reactor incorporates flow diversion means (80; 88) such that the first fluid must flow through at least three such first flow channels (76) in succession, in flowing from an inlet to an outlet. The overall flow paths can therefore be approximately co-current or counter-current.