Endothermic reaction of a feed gas heated by resistance heating

Patent metadata

Field	Value
Publication number	US-12415174-B2
Application number	US-202017781910-A
Country	US
Kind code	B2
Filing date	Dec 3, 2020
Priority date	Dec 4, 2019
Publication date	Sep 16, 2025
Grant date	Sep 16, 2025

Abstract

Array including a first and a second monolith of a structured catalyst for carrying out an endothermic reaction of a feed gas, wherein: a) the first and second monolith include a macroscopic structure of a first and second electrically conductive material; b) each of said first and second monoliths has a number of flow channels formed therein for conveying feed gas through the monoliths; c) the array includes at least a first and a second conductor electrically connected to said first and second monoliths, respectively, and to an electrical power supply, d) the first and second monolith are electrically connected by a monolith bridge; e) the array is configured to direct an electrical current to run from the first conductor through the first monolith to a second end, then through the bridge, and then through the second monolith to the second conductor.

First claim

The invention claimed is:

1. An array comprising a first and a second monolith of a structured catalyst for carrying out an endothermic reaction of a feed gas, wherein:
a) the first and second monolith comprises a macroscopic structure of a first and second electrically conductive material, respectively, said macroscopic structure supporting a ceramic coating, wherein said ceramic coating supports a catalytically active material;
b) each of said first and second monoliths has a number of flow channels formed therein for conveying said feed gas through the monoliths from a first end, where the feed gas enters, to a second end, where a product gas exits, wherein each of said first and second monoliths has a longitudinal axis extending from said first end to said second end;
c) the array comprises at least a first and a second conductor electrically connected to said first and second monoliths, respectively, and to an electrical power supply, wherein said electrical power supply is dimensioned to heat at least part of said first and second monoliths to a temperature of at least 500° C. by passing an electrical current through said macroscopic structure, wherein said first conductor is electrically connected directly or indirectly to the first monolith and the second conductor is electrically connected directly or indirectly to the second monolith, and wherein the conductors are connected at positions on the array closer to said first end than to said second end,
d) said first and second monolith are electrically connected by a monolith bridge of a monolith bridge electrically conductive material;
e) the array is configured to direct an electrical current to run from the first conductor through the first monolith to said second end, then through the bridge, and then through the second monolith to the second conductor; and
f) said array has been produced by a process comprising the steps of:
i) providing the electrically conductive materials of the first monolith, the second monolith and the monolith bridge in the form of three separate entities, and
ii) joining the separate entities together by a method comprising a step of sintering or oxidizing treatment.

2. Array according to claim 1 , wherein the monolith bridge material is devoid of any flow channels for conveying said feed gas.

3. Array according to claim 1 , wherein the monolith bridge material is a material devoid of any space with a smallest dimension of 0.4 mm or more formed therein.

4. Array according to claim 1 , wherein the sintering or oxidizing treatment has resulted an array in which there is no apparent separation or interface between the former interfaces between the first monolith, the second monolith, and the monolith bridge when visually analyzing the joined entities by use of Scanning Electron Microscopy analysis.

5. Array according to claim 1 , wherein the electrically conductive materials of the monoliths and the monolith bridge are the same material.

6. Array according to claim 1 , wherein the second conductor is indirectly electrically connected to the second monolith.

7. Array according to claim 6 , wherein the array further comprises (i) one or more juxtaposed additional intermediate monoliths of a structured catalyst and (ii) one end monolith of a structured catalyst, wherein each additional intermediate monolith is connected to at least two juxtaposed monoliths by a monolith bridge of a monolith bridge electrically conductive material, and wherein the end monolith is connected to at least one juxtaposed monolith, and wherein the second conductor is connected to the end monolith at a position on the monolith closer to said first end than to said second end.

8. Array according to claim 7 , wherein the total of the additional intermediate monoliths and the end monolith is an even integer, and wherein the second conductor is connected to the end monolith at the first end of the array.

9. Array according to claim 8 , wherein the first and second monoliths are connected by the monolith bridge at the second end of the array, wherein each additional intermediate monolith is serially connected to two juxtaposed monoliths by a monolith bridge of a monolith bridge electrically conductive material alternately at said first end and at said second end so as to direct the current from one end to the opposite end of each monolith, and wherein the end monolith is connected to one juxtaposed monolith at the second end.

10. Array according to claim 1 , wherein the said first and second monoliths are connected by the monolith bridge at the second end of the array.

11. Array according to claim 1 , wherein the monolith bridge extends over less than 50%, of the length from the first to the second ends of the first and second monoliths.

12. Array according to claim 1 , wherein said array has been produced by a process of comprising the steps of:
A) providing the electrically conductive materials of the first monolith, the second monolith and the monolith bridge in the form of three separate entities, wherein the surface areas to be connected are in a moldable state,
B) contacting the surface areas to be connected in the contact areas, and
C) joining the contact areas together by a method comprising a step of sintering or oxidizing treatment.

13. Array according to claim 1 , wherein said array has been produced by a process of comprising the steps of:
providing a first monolith component comprising metal powder with a first alloy composition and a first soluble binder, the first component having a first joining surface;
providing a second monolith component comprising metal powder with a second alloy composition and a second soluble binder, the second component having a second joining surface;
providing a bridge component comprising metal powder with a third alloy composition and a third soluble binder, the bridge component having two third joining surfaces, one at each end of the bridge component;
wherein the first alloy composition and the second and third alloy compositions all consist of a plurality of chemical elements, and wherein the chemical elements are chosen so that, for each of the chemical elements being present in an amount higher than 0.5 weight % of the respective alloy composition, that chemical element is comprised both in the first and second and third alloy composition, and
for the chemical elements being present in the first alloy composition in amounts of up to 5.0 weight %, the amount of that chemical element differs by at most 1 percentage point between the first alloy composition on the one hand and each of the second and third alloy compositions on the other hand, and
for the chemical elements being present in the first alloy composition in amounts of more than 5.0 weight %, the amount of that chemical element differs by at most 3 percentage point between the first alloy composition on the one hand and each of the second and third alloy compositions on the other hand, and

arranging the bridge component between the first monolith component and the second monolith component so that one third joining surface contacts the first joining surface and that the other third joining surface contacts the second joining surface;
maintaining the joining surfaces in contact for a time period; and
subsequently sintering or oxidizing the first, second and third components together while maintaining the joining surfaces in contact or as close together as possible in order to achieve the array.

14. Array according to claim 13 , wherein the following step precedes the step of arranging:
at least partly dissolving the first joining surface and/or the second joining

Assignees

• Haldor Topsoe As
• Grundfos Holding As

Inventors

• Mortensen Peter Mølgaard
• Larsen Kasper Emil
• Aasberg-Petersen Kim
• Wismann Sebastian Thor
• Sorea Alexandru
• Valler Peter
• Buus Bendixen Flemming
• Søgaard Allan Ivo
• Rasmussen Henrik

Classifications

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• B01J35/33

  Electric or magnetic properties · CPC title

• C01B2203/1241

  Natural gas or methane · CPC title

• C01B2203/1023

  Catalysts in the form of a monolith or honeycomb · CPC title

• C01B2203/085

  by electric heating · CPC title