Patent ID: 8354083

Claim:
A method for assembling a multi-tubular reactor for processing a fluid stream in a processing temperature range, the reactor incorporating an array of reactor tubes filled with one or more monolith segments of a monolithic catalyst or catalyst support, which comprises the steps of: selecting a monolith segment of a monolithic catalyst or catalyst support structure, the segment being formed of a heat-conductive material having a first average linear coefficient of thermal expansion; selecting a reactor tube formed of a heat-conductive material having a second average linear coefficient of thermal expansion, wherein the first average linear coefficient of thermal expansion is greater than the second average linear coefficient of thermal expansion; sizing the monolith segment and/or the reactor tube to dimensions effective to provide (i) a non-interfering fit between the monolith segment and the reactor tube when each is at a selected monolith mounting temperature and when each is at ambient temperature at reactor shut-down, and (ii) an average gap distance between the reactor tube and the segment not exceeding about 250 μm when the monolith segment is filled with fluid at a temperature in the processing temperature range; and inserting the segment into the reactor tube.