CATALYTIC REACTOR DESIGNED TO REDUCE CATALYST SLUMPING AND CRUSHING

Abstract: A vertical catalytic reactor for steam reforming a reactor fuel into a product gas, the catalytic reactor containing a catalyst forming a catalyst bed. If the catalytic reactor material has a thermal coefficient of expansion greater than the catalyst, then the catalytic reactor experiences problems due to thermal cycling. During the start-up of the catalytic reactor, the temperature increase causes the catalytic reactor to expand more than the catalyst, thus, the catalyst slumps within the catalytic reactor. During the shut-down of the catalytic reactor, the temperature decrease causes the catalytic reactor to contract and crush the slumped catalyst. The catalytic reactor incorporates a design (100) for reducing catalyst slumping and crushing.

Description: Description CATALYTIC REACTOR DESIGNED TO REDUCE CATALYST SLUMPING AND CRUSHING Technical Field The present invention relates to an improved catalytic reactor and particularly to a catalytic reactor which resists catalyst slumping and crushing. Background of the Invention The steam reformation of a reactor fuel, such as a hydrocarbon fuel, into a useful product gas, is well known in the art. This steam reformation is accomplished by causing the reactor fuel and steam to contact a heated catalyst bed. Fig. 1 , shows a cross-sectional view of a prior art catalytic reaction apparatus 10 for just such purpose. The apparatus 10 comprises a furnace 12 which is the heat source for the reformation process and at least one vertical catalytic reactor 14. The furnace 12 has furnace walls 16 arranged to define a furnace volume 18, an inlet 20 for introducing air 22 into the furnace volume 18, an injection means 24 for introducing a furnace fuel 26 into the furnace volume 18 thereby producing the hot combustion gases 28, and an exhaust 30 for removing the combustion gases 28. The furnace volume 18 is divided into a burner cavity 32 where the combustion gases 28 originate and a heat transfer section 34 positioned below the burner cavity 32. The heat transfer section 34 has an annular combustion gas passageway 36 for flow of the combustion gases 28. The combustion gas passageway 36 extends along the outside of the catalytic reactor 14 from the burner cavity 32 through the heat transfer section 34 to the exhaust 30. The combustion gas passageway 36 may or may not be filled with solid particles or other materials (not shown), which assist in transferring heat from the combustion gases 28 to the catalytic reactor 14. The catalytic reactor 14 disposed within the combustion gas passageway 36 of the furnace 12 has a hot section 38 disposed within the burner cavity 32 and a cooler section 40 disposed within the heat transfer section 34. Each catalytic reactor 14 has an axis of symmetry A and comprises a reactor tube 42 and a cap 44, which seals the tube 42 at the top. The reactor tube 42 consists of an outer reactor wall 46 exposed to the combustion gases 28, and an inner reactor wall 48 which is spaced away from the outer reactor wall 46 defining an annular reaction chamber 50 between the reactor walls 46, 48. The reaction chamber 50 has an inlet 52 disposed within the reaction chamber 50 for entry of a reactor fuel and steam 54, an outlet 56 disposed within the reaction chamber 50 spaced away from the inlet 52 for exit of the product gas 58 from the reaction chamber 50, a catalyst 60 disposed within the reaction chamber 50 forming a catalyst bed 62 for aiding in the reformation, and an annular support plate 64 disposed within the reaction chamber 50 for supporting the catalyst bed 62. There are a multiplicity of holes (not shown) disposed through the support plate 64. The catalytic reaction apparatus 10 can utilize any conventional catalytic reactor 14 capable of withstanding the desired operating temperatures and thermal cycles within the furnace 12. Typically temperatures and thermal cycles are up to about 1 ,600°F. Generally, the catalytic reactor 14 is a stainless steel tube or similar hollow structure. Some such conventional catalytic reactors are disclosed in U.S. Patent No. 4,071,330, U.S. Patent No. 4,098,587, U.S. Patent No. 4,098,588, U.S. Patent No. 4,098,589, and U.S. Patent No. 4,203,950. The catalyst 60 used is a steam reforming catalyst well known by one of ordinary skill in the art. The catalyst is typically in the shape of spheres, pellets or Raschig rings. Within the reaction chamber 50, the weight of the catalyst 60 within the catalyst bed 62 is distributed downward throughout the catalyst bed 62 and born by the support plate 64. In operation, the combustion gases 28 flow from the burner cavity 32 along the outside of the reactor 14 through the combustion gas passageway 36 and out the exhaust 30. A mixture of the reactor fuel and steam 54 enter through the reactor inlet 52 and flow through the reaction chamber 50. Thus, the combustion gases 28 and the reactor fuel and steam 54 are flowing counter-current in a heat exchange relationship. The heat exchange relationship and radiant heat from the furnace walls 16 drive the steam reforming reaction within the reaction chamber 50 between the reactor fuel and steam 54 and the catalyst 60, thus producing the product gas 58. The product gas 58 exits the reaction chamber 50 through the outlet 56. In industry, the product gas 58 is typically hydrogen-rich. The catalytic reactor 14 experiences a problem due to thermal cycling. During start-up the catalytic reactor 14 temperature increases and the reactor walls 46, 48 and catalyst 60 expand at different rates. The volume between the reactor walls 46, 48 or the volume of the reaction chamber 50 expands more than the volume of the catalyst 60 because the reactor walls 46, 48 have a higher coefficient of thermal expansion than the catalyst 60. The outer reactor wall 46 expands most because it is in direct contact with the combustion gases 28, while the inner reactor wall 48 also expands, but not as much. The catalyst 60 expands least due to the low coefficient of thermal expansion, resulting in a catalyst volume less than the new volume of the reaction chamber 50. Consequently, once the reactor walls 46, 48 expand, gravity acting upon the catalyst 60 causes the catalyst 60 to move downward in the reaction chamber 50 filling voids caused by the increase in volume. This process is known as catalyst "slumping". Slumping will occur in any conventional catalytic reactor or container having solid particles, such as a catalyst or other solid heat transfer material; having a thermal coefficient of expansion greater than that of the solid particles; exposed to a heat source; and positioned in a vertical arrangement. During shut-down when the catalytic reactor 14 cools, the reactor walls 46, 48 contract; however, since the catalyst 60 has been redistributed downward, cooling of the catalytic reactor 14 results in the reactor walls 46, 48 exerting mechanical pressure on the catalyst 60. When the mechanical pressure is applied, the weight of the catalyst bed 62 and the friction forces between the catalyst 60 and the reactor walls 46, 48 prevent the catalyst 60 from rising in the catalytic reactor 14. A portion of this mechanical pressure is adsorbed by the catalyst 60 and the reactor walls 46, 48 while the remainder crushes some of the catalyst 60 into catalyst particles (not shown). Catalyst 60 slumping and crushing causes several problems within the catalytic reactor 14. The resulting catalyst particles (not shown) have a higher drag coefficient than the original catalyst 60 so the product gas 58 may lift the catalyst particles (not shown) out of the reaction chamber 50. The first effect of the catalyst 60 loss is a decrease in the fuel conversion rate in the hot section 38 of the catalytic reactor 14. This requires that the catalytic reactor 14 be operated at ever increasing temperatures to achieve the desired fuel conversion. Another effect is that the catalytic reactor 14 may have to be prematurely shutdown. Typically, reactors are designed to operate a number of years with multiple start-up/shut-down thermal cycles per year, resulting in a series of thermal cycles, each one of which is associated with the slumping and crushing of some catalyst 60. When enough catalyst 60 is lost so that the efficiency of the catalytic reactor 14 has decreased sufficiently, the catalytic reactor 14 may have to be shutdown and new catalyst 60 loaded. Further, if enough catalyst 60 is crushed so that voids in the catalyst 60 are reduced, the catalytic reactor 14 may become clogged, thereby unacceptably restricting the flow of the reactor fuel and steam 54 through the catalyst bed 62. Thus, clogging may make it necessary to remove the catalyst 60 and insert new catalyst 60. A reactor designed to reduce catalyst slumping and crushing is described in U.S. Patent No. 4,203,950, incorporated herein by reference in its entirety. The reactor disclosed in U.S. Patent No. 4,203,950, addresses catalyst slumping and crushing by reducing the mechanical pressure of the reactor wails on the catalyst. An optimal mechanical pressure range is determined and the catalytic reactor and the catalyst are design to conform to that range. Although the catalytic reactor disclosed in U.S. Patent No. 4,203,950 significantly reduces the problem of catalyst slumping and crushing due to thermal cycling, the solution taught by U.S. Patent No. 4,203,950 requires that certain variables with respect to the design of the catalytic reactor and the catalyst, such as dimensions and elasticity ranges, be within certain values. Since the catalytic reactors must be built to that teaching, this solution cannot be applied to existing catalytic reactors. Also, the design set forth in U.S. Patent No. 4,203,950 does not solve the problem of slumping and crushing for catalytic reactors which by their design cannot conform to the optimum mechanical pressure range due to operating conditions which require a large number of thermal cycles or catalytic reactors of a increased height or diameter. What is needed in the art is an improved catalytic reaction apparatus which further reduces catalyst slumping and crushing, thus, increasing the efficiency of the apparatus. It is an object of the present invention to solve catalyst crushing in a manner that can be applied to existing catalytic reactors. Disclosure of the Invention According to the present invention, a vertical catalytic reactor for steam reforming a reactor fuel into a product gas, designed to reduce catalyst slumping and crushing is disclosed. The catalytic reactor is filled with a catalyst forming a catalyst bed such that the reactor fuel and steam flow in contact with the catalyst bed. The catalytic reactor has a thermal coefficient of expansion greater than that of the catalyst and is subject to a temperature cycle sufficient to change the volume within the catalytic reactor permitting the catalyst to slump and be crushed. The catalytic reactor has a plurality of fixtures for dividing the catalyst bed into a plurality of catalyst sections. The catalyst sections and fixtures having a weight. The fixtures being disposed within the catalytic reactor such that there is a first fixture and second fixture. The first fixture is below the second fixture, and the first and second fixtures contain the first and second catalyst sections, respectively. Each fixture having a base coupled to a number of vertical support means. The base for dividing the catalyst bed into the catalyst sections has a perforated plate. The perforated plate has a multiplicity of holes capable of retaining the catalyst while allowing the flow of the reactor fuel and steam in contact with the catalyst section. The vertical support means for supporting the weight of the second fixture and the weight of the second catalyst section transmit the weight of the second fixture and the weight of the second catalyst section to the first fixture. Brief Description of the Drawings Fig. 1 is a cross-sectional view of a prior art catalytic reaction apparatus in which a plurality of fixtures (not shown) of the present invention can be employed. Fig. 2 is an isometric view of one embodiment of a fixture. Fig. 3 is an enlarged view of the area within the line 3 of Fig. 1 , showing the disposition of a plurality of fixtures within a reaction chamber. These figures are meant to be exemplary and not to limit the generally broad scope of the present invention. Best Mode of Carrying Out the Invention Fig. 2 is an isometric view of one embodiment of a fixture 100. Fixture as used in this description and in the appended claims means a structure for dividing a catalyst bed (not shown) into a plurality of catalyst sections (not shown). The fixture 100 has a base 102 for dividing the catalyst bed (not shown) into the catalyst sections (not shown). Coupled to the base 102 is a number of vertical support means 104 for supporting the weight of a second fixture and catalyst within the second fixture (not shown). The fixture 100 has an axis of symmetry A. In this embodiment, the base 102 is an annular perforated plate 106 coupled to an annular stiffening member 108. The perforated plate 106 has a multiplicity of holes disposed through its surface, represented by the holes 110. The holes 110 should be capable of retaining the catalyst (not shown) while allowing the flow of the reactor fuel and steam (not shown) in contact with the catalyst bed (not shown). The vertical support means 104 in this embodiment are a plurality of rods, represented by the rod 112, coupled circumf erentially about the stiffening member 108. Each rod 112 has a first end 114 opposed to a second end 116. The first end 114 is attached to the stiffening member 108 and the rod 112 extends upwardly from the stiffening member 108, parallel to the axis of symmetry A to terminate with the second end 116. Each of the plurality of rods 112 has a referencing means 118 attached at the second end 116. The referencing means 118 is used as a visual reference so that each fixture 100 is not overloaded with catalyst (not shown). The referencing means 118 in this embodiment is a disk. Other embodiments may employ rods 112 with 90° angles at the second end 116 instead of a referencing means 118, or rods with a ring at the second end 116, so long as the rods 112 maintain the distance between adjacent perforated plates (not shown) without imparting the weight of the superjacent catalyst section and fixture (not shown) to the subjacent catalyst section (not shown). The fixture 100 in this embodiment is made of stainless steel and designed to withstand the thermal cycles and the weight of the catalyst section (not shown); however, any material that can satisfy these requirements can be utilized. Several characteristics of the fixture 100, such as the number of rods 112 and the dimensions of the rods 112, the stiffening member 108, and the perforated plate 106 are based upon the necessary structural integrity of the fixture 100 and its ability to support the catalyst section (not shown). Since the stiffening member 108 is rigidly attached to the perforated plate 106, the stiffening member 108 provides additional strength and rigidity to the perforated plate 106, thus, decreasing the necessary plate thickness t (not shown). Other embodiments of the fixture 100 may eliminate the stiffening member 108 in favor of a more substantial perforated plate 106. Fig. 3 is an enlarged view of the area within the line 3 of Fig. 1 , showing the disposition of a plurality of fixtures 100 within a reaction chamber 50. The perforated support plate 64 is disposed within the reaction chamber 50 and has a multiplicity of holes represented by the holes 120. The support plate 64 is rigidly attached to the inner reactor wall 48. The distance between the inner reactor wall 48 and the outer reactor wall 46 is the reaction chamber width w r . Resting on the support plate 64 is a standoff 122. Superjacent to the standoff 122 is the first fixture 100a, which contains the first catalyst section 124a. Above the first fixture 100a is the second fixture 100b which contains the second catalyst section 124b. It should be understood that a multiple number of fixtures may be used as necessary although the catalytic reaction chamber 50 shown in Fig. 3 only has two fixtures 100a, b. The standoff 122 allows the flow of the reactor fuel and steam 54 to be uninterrupted by a possible misalignment of the first fixture 100a with the support plate 64. The standoff 122 can be any means for separating the support plate 64 from the perforated plate 106a of the first fixture 100a, such as a permanent fixture or a support plate coupled with a number of vertical support means 104 similar to that for the fixtures. However, in this embodiment, the standoff 122 is a steel ring. In this embodiment, each fixture 100a, b consists of a perforated plate 106a, b, a stiffening member 108a, b and a plurality of rods, represented by the rod 112a, b. Each perforated plate 106a, b has a multiplicity of holes represented by the holes 110a, b, respectively. Each rod 112a, b is attached to the stiffening member 108a, b with a rod weld 126a, b. The perforated plates 106a, b are attached to the other side of the stiffening member 108a, b with a base weld 128a, b. Although in the embodiment shown the rods 112a, b extend from the stiffening member 108a, b upward, it is understood by those skilled in the art that the fixtures 100a, b can be designed such that the rods 112a, b extend from the stiffening member 108a, b downward, in which case the standoff 122 may not be necessary. Each rod has a length l s . The perforated plates 106a, b have a thickness t, an inner diameter dj, an outer diameter d 0 , and a width w p which is the distance from the inner diameter dj to the outer diameter d 0 . The perforated plate width w p must be less than the reaction chamber width w r , to allow easy installation of the fixtures 100a, b within the reaction chamber 50. The stiffening members 108a, b have a diameter d s . Each fixture 100a, b has a height h defined by the length l s of each rod 112a, b added to the diameter d s of each stiffening member 108a, b. The preferred fixture height h varies throughout the catalytic reactor 14 based upon the thermal cycle and the weight that the fixture must support, which corresponds to the location of the fixture within the catalytic reactor 14. The preferred fixture height h will allow the catalyst within a given section to resist an acceptable amount of slumping and crushing for the operating life of the catalytic reactor. In practice, as shown in Fig. 1 , the fixtures (not shown) are used in a vertical catalytic reactor. A vertical catalytic reactor 14 is intended to describe a catalytic reactor where the catalyst 60 material located within the catalytic reactor 14 is subject to the slumping problem. Before the reactor cap 44 is welded to the reactor tube 42, the reaction chamber 50 is loaded. Referring to Figs. 1, 2 and 3 as necessary, first the standoff 122 is placed on the support plate 64. Then the first fixture 100a is inserted into the reaction chamber 50, such that the axis of symmetry A of the catalytic reactor 14 and the fixture 100a are aligned. The first fixture 100a is then filled with the first catalyst section 124a utilizing the referencing means 118 at the second end 116 of the rod 112. Next, the second fixture 100b is loaded into the reaction chamber 50 so that the rods 112b on the second fixture 100b are aligned with the rods 112a of the first fixture 100a. This limits the bending load and lateral transverse stress experienced by the fixtures 100a, b, and decreasing the structural requirements of the material of which the fixtures 100a, b are made. Reaction chamber 50 loading is completed by alternately loading additional catalyst sections (not shown) and fixtures (not shown) in the aforementioned manner until the reaction chamber 50 is filled with catalyst 60 to the necessary height, which is well known in the art. Referring to Fig. 1 , once loading is complete, the reactor cap 44 is welded to the reactor tube 42. During the temperature increase at start-up, with the fixtures 100a, b within the reaction chamber 50, the first catalyst section 124a bears only the weight of the first catalyst section 124a, while the weight of second fixture 100b and second catalyst section 124b are supported by the first fixture 100a through the rods 112a. This decrease in weight results in only minimal local slumping within each fixture 100a, b and minimal catalyst movement from the second fixture 100b to the first fixture 100a. During cool down, as the reactor walls 46, 48 contract, they exert mechanical pressure on the slumped catalyst sections 124a, b. However, due to the support of the superjacent catalysts' weight, most of the slumped catalyst being unrestrained is free to move upward within its section under the mechanical pressure instead of crushing. Thus, only minimal crushing of the catalyst occurs. While the particular invention has been described with reference to illustrative embodiments, this description is not meant to be construed in a limiting sense. It is understood that although the present invention has been described in a preferred embodiment, various modifications of the illustrative embodiments, as well as additional embodiments of the invention, will be apparent to persons skilled in the art upon reference to this description without departing from the spirit of the claimed invention, as recited in the claims appended hereto. It is therefore contemplated that the appended claims will cover any such modifications or embodiments as fall within the true scope of the invention. For example, utilizing the present invention to prevent slumping and crushing of any solid particles, such as the heat transferring material within the combustion gas passageway. We claim:

Claims: Claims 1. A vertical catalytic reactor for steam reforming a reactor fuel into a product gas, said catalytic reactor having a catalyst disposed therein forming a catalyst bed, such that the reactor fuel and steam flow in contact with the catalyst bed, said catalytic reactor also having a thermal coefficient of expansion greater than that of the catalyst and is subject to a temperature cycle sufficient to change the volume within the catalytic reactor permitting the catalyst to slump and be crushed, the catalytic reactor comprising: a plurality of fixtures for dividing the catalyst bed into a plurality of catalyst sections, said catalyst sections and fixtures having a weight, said fixtures being disposed within the catalytic reactor such that there is a first fixture and a second fixture, said first fixture disposed below the second fixture and said first and second fixtures containing the first and second catalyst sections respectively therein, each fixture further comprising, i. a base for dividing the catalyst bed into the catalyst sections, said base having a perforated plate having a multiplicity of holes capable of retaining the catalyst while allowing the flow of the reactor fuel and steam in contact with the catalyst sections; and ii. a number of vertical support means for supporting the weight of the second fixture and the weight of the second catalyst section, said vertical support means being coupled to the base, said vertical support means transmit the weight of the second fixture and the weight of the second catalyst section to the first fixture. 2. The catalytic reactor as in claim 1 , wherein the base further comprises: a stiffening member coupled to said perforated plate. 3. The catalytic reactor as in claim 1 , wherein the number of vertical support means further comprise: a plurality of rods disposed about the base. 4. The catalytic reactor as in claim 1 , wherein the number of vertical support means further comprise: a plurality of rods disposed about the base, where said rods for the second fixture are approximately aligned with the rods for the first fixture, whereby limiting the bending load and lateral transverse stress experienced by the first and second fixtures. 5. The catalytic reactor as in claim 1 , wherein the vertical support means further comprises: a plurality of rods, each rod having a first end coupled to the base and a second end opposite the first end, said rods having a referencing means attached to the second end for aiding in loading of the catalyst 6. A vertical catalytic reactor for steam reforming a reactor fuel into a product gas, said catalytic reactor having a catalyst disposed therein forming a catalyst bed, such that the reactor fuel and steam flow in contact with the catalyst bed, said catalytic reactor also having a thermal coefficient of expansion greater than that of the catalyst and is subject to a temperature cycle sufficient to change the volume within the catalytic reactor permitting the catalyst to slump and be crushed, the catalytic reactor comprising: a fixture for dividing the catalyst bed into a plurality of catalyst sections, said catalyst sections and fixture having a weight, said fixture being disposed within the catalytic reactor such that said fixture contains a first catalyst section and has a second catalyst section above the fixture, said fixture further comprising, i. a base for dividing the catalyst bed into the catalyst sections, said base having a perforated plate having a multiplicity of holes capable of retaining the catalyst while allowing the flow of the reactor fuel and steam in contact with the catalyst section; and ii. a number of vertical support means for supporting the weight of the second catalyst section, said vertical support means being coupled to the base, said vertical support means transmit the weight of the fixture and the weight of the second catalyst section to the catalytic reactor. 7. The catalytic reactor as in claim 6, wherein the base further comprises: a stiffening member coupled to said perforated plate. 8. The catalytic reactor as in claim 6, wherein the number of vertical support means further comprise: a plurality of rods disposed about the base. 9. A vertical catalytic reactor for steam reforming a reactor fuel into a product gas, said catalytic reactor having an outer reactor wall, an inner reactor wail, said inner reactor wall spaced from said outer reactor wall defining a reaction chamber between said outer and inner reactor walls, said reaction chamber having an inlet disposed within the reaction chamber for entry of the reactor fuel and steam, an outlet disposed within the reaction chamber spaced away from the inlet for exit of the product gas, a catalyst disposed within the reaction chamber forming a catalyst bed such that the reactor fuel and steam flow in contact with the catalyst bed, and a support plate disposed within the reaction chamber for supporting the catalyst bed, the catalytic reactor comprising: a plurality of fixtures for dividing the catalyst bed into a plurality of catalyst sections, said catalyst sections and fixtures having a weight, said fixtures being disposed within the reaction chamber such that there is a first fixture and a second fixture, said first fixture disposed below the second fixture and said first and second fixtures containing the first and second catalyst sections, respectively, therein, each fixture further comprising, i. a perforated plate for dividing the catalyst bed into catalyst sections, said plate having a multiplicity of holes capable of retaining the catalyst while allowing the flow of the reactor fuel and steam in contact with the catalyst section, ii. a stiffening member coupled to said perforated plate, iii. a plurality of rods for supporting the weight of the second fixture and the weight of the second catalyst section, said rods disposed about the stiffening member, where said rods for the second fixture are approximately aligned with the rods for the first fixture, each rod further comprising, a first end coupled to the stiffening member, and a second end at the opposite end of the rod, said rods transmit the weight of the second fixture and the weight of the second catalyst section to the first fixture; and iv. a plurality of referencing means for aiding in loading of the catalyst, one referencing means attached to the second end of each rod. 10. A fixture for dividing a solid particle bed into a plurality of solid particle sections, said solid particle sections and fixture having a weight, said fixture further comprising, i. a perforated plate for dividing the solid particle bed into said solid particle sections, said perforated plate having a multiplicity of holes capable of retaining the solid particles while allowing the flow of a gas through said solid particle section, and ii. a plurality of rods for supporting the weight of the solid particles above the fixture, said rods disposed about the perforated plate.

Inventors: BONK STANLEY O, CORRIGAN THOMAS J, SEDERQUIST RICHARD A, SZYDLOWSKI DONALD F, BONK, STANLEY, O., CORRIGAN, THOMAS, J., SEDERQUIST, RICHARD, A., SZYDLOWSKI, DONALD, F.
Applicants: INT FUEL CELLS CORP, INTERNATIONAL FUEL CELLS CORPORATION
Application year: 1995
Main classification: B01J8
IPC codes: B01J8, C01B3, H01M8