Cdr reactor having multilayered catalyst layer arrangement for preventing catalyst deactivation

Patent metadata

Field	Value
Publication number	US-2022016590-A1
Application number	US-201917296152-A
Country	US
Kind code	A1
Filing date	Nov 22, 2019
Priority date	Nov 23, 2018
Publication date	Jan 20, 2022
Grant date	—

Abstract

Proposed is a carbon dioxide reforming (CDR) reactor having a multilayered catalyst layer arrangement for preventing catalyst deactivation, wherein, in the reactor in which a CDR reaction for reacting methane (CH 4 ) with carbon dioxide (CO 2 ) to reform the methane into a synthesis gas including carbon monoxide (CO) and hydrogen (H 2 ) is performed, in order to prevent a case where an endothermic reaction between a catalyst and heated reactant gas supplied to the reactor gradually causes the temperature of the reactant gas to decrease and the catalyst is deactivated by cokes generated due to the decrease in temperature of the reactant gas, CDR catalysts in the reactor are arranged in multiple layers in a multilayered structure to allow the reactant gas temperature that has decreased due to the endothermic reaction to be restored in spaces between the catalyst layers.

First claim

1 . A CDR reactor, comprising:
a reactor housing including a reactant gas inlet formed at a first side thereof and allowing introduction of reactant gas including methane and carbon dioxide, an outlet formed at a second side thereof and allowing discharge of unreacted gas and reaction products, and a heating means provided in a housing wall at a position between the reactant gas inlet and the outlet and heating the reactant gas inside the reactor housing; and a catalytic reaction part provided inside the reactor housing and having a structure in which CDR catalyst layers are arranged in multiple layers in a direction from the reactant gas inlet toward the outlet, wherein in order to prevent a temperature of the reactant gas in the reactor from decreasing to equal to or less than 750° C., while maintaining a final conversion rate of the reactant gas based on methane in a single reactor equal to or greater than 90%, the catalytic reaction part is configured such that the CDR catalyst layers are arranged in multiple layers so as to be spaced apart from each other at a predetermined interval, and a temperature restoration section having a length equal to the predetermined interval is formed between each of the catalyst layers, wherein in the temperature restoration section, the reactant gas having a decreased temperature due to an endothermic reaction while passing through each of the catalyst layers is reheated by the heating means.

2 . The CDR reactor of claim 1 , wherein the CDR catalyst layers are configured to have thicknesses equal or increased in the direction from the reactant gas inlet toward the outlet, and the respective temperature restoration sections are configured to have lengths equal or decreased in the direction from the reactant gas inlet toward the outlet.

3 . The CDR reactor of claim 1 , wherein the catalytic reaction part is configured such that when a region in which thicknesses of adjacent catalyst layers are equal to each other exists, lengths of the temperature restoration sections are decreased in the region in the direction from the reactant gas inlet toward the outlet.

4 . The CDR reactor of claim 1 , wherein the catalytic reaction part is configured such that when a region in which lengths of adjacent temperature restoration sections are equal to each other exists, thicknesses of the CDR catalyst layers are increased in the region in the direction from the reactant gas inlet toward the outlet.

5 . The CDR reactor of claim 1 , wherein each of the CDR catalyst layers comprises a catalyst having a monolithic structure including nickel, cobalt, ruthenium, and zirconium.

6 . The CDR reactor of claim 1 , wherein the catalytic reaction part is configured such that a catalyst layer with which the reactant gas firstly comes into contact is spaced apart from the reactant gas inlet to allow the reactant gas to be preheated to a reaction temperature.

7 . The CDR reactor of claim 1 , wherein arrangement of the catalytic reaction part is such that the CDR catalyst layers are arranged in multiple layers so as to be spaced apart from each other at the predetermined interval in order to prevent the temperature of the reactant gas from decreasing to equal to or less than 800° C., and the interval between each of the catalyst layers becomes the temperature restoration section where the temperature of the reactant gas is restored to an initial temperature.

8 . A carbon dioxide reforming method of methane using a multilayered catalyst layer arrangement for preventing catalyst deactivation, the carbon dioxide reforming method comprising:
supplying reactant gas into a reactor housing, the reactor including a reactant gas inlet formed at a first side thereof and allowing introduction of the reactant gas including methane and carbon dioxide, an outlet formed at a second side thereof and allowing discharge of unreacted gas and reaction products, and a heating means provided in a housing wall at a position between the reactant gas inlet and the outlet; performing a CDR reaction as the reactant gas comes into contact with each of CDR catalyst layers, the catalyst layers being arranged in multiple layers in the reactor housing so as to be spaced apart from each other at a predetermined interval in a direction from the reactant gas inlet toward the outlet in order to prevent a temperature of the reactant gas from decreasing to equal to or less than 750° C. while maintaining a final conversion rate of the reactant gas based on methane in a single reactor equal to or greater than 90%; reheating, by the heating means, the reactant gas having a decreased temperature due to an endothermic reaction while passing through each of the catalyst layers in each of spaces, each space being defined between each of the catalyst layers as a result of arranging the CDR catalyst layers in multiple layers so as to be spaced apart from each other at the predetermined interval; and discharging unreacted gas and reaction products through the outlet, wherein the performing of the CDR reaction and the reheating of the reactant gas are alternately performed a number of times equal to the number of the CDR catalyst layers arranged in multiple layers.

9 . The carbon dioxide reforming method of claim 8 , wherein the performing of the CDR reaction is performed in each of the CDR catalyst layers, each CDR catalyst layer comprising a catalyst having a monolithic structure including nickel, cobalt, ruthenium, and zirconium.

10 . The carbon dioxide reforming method of claim 8 , wherein in the performing of the CDR reaction, the CDR catalyst layers are arranged in multiple layers so as to be spaced apart from each other at the predetermined interval in order to prevent the temperature of the reactant gas from decreasing to equal to or less than 800° C., and the interval between each of the catalyst layers becomes a temperature restoration section where the temperature of the reactant gas is restored to an initial temperature.

11 . The CDR reactor of claim 2 , wherein arrangement of the catalytic reaction part is such that the CDR catalyst layers are arranged in multiple layers so as to be spaced apart from each other at the predetermined interval in order to prevent the temperature of the reactant gas from decreasing to equal to or less than 800° C., and the interval between each of the catalyst layers becomes the temperature restoration section where the temperature of the reactant gas is restored to an initial temperature.

12 . The CDR reactor of claim 3 , wherein arrangement of the catalytic reaction part is such that the CDR catalyst layers are arranged in multiple layers so as to be spaced apart from each other at the predetermined interval in order to prevent the temperature of the reactant gas from decreasing to equal to or less than 800° C., and the interval between each of the catalyst layers becomes the temperature restoration section where the temperature of the reactant gas is restored to an initial temperature.

13 . The CDR reactor of claim 4 , wherein arrangement of the catalytic reaction part is such that the CDR catalyst layers are arranged in multiple layers so as to be spaced apart from each other at the predetermined interval in order to prevent the temperature of the reactant gas from decreasing to equal to or less than 800° C., and the interval between each of the catalyst layers becomes the temperature restoration section where the temperature of the reactant gas is restored to an initial temperature.

14 . The CDR reactor of claim 5 , wherein arrangement of the catalytic reaction part is such that the CDR catalyst layers are arranged in multiple layers s

Assignees

• Korea Res Inst Chemical Tech

Inventors

• Chang Tae Sun
• Heo Iljeong
• Park Jung Hyun
• Kim Beom Sik
• Park Ji Hoon
• Lee Jin Hee

Classifications

• Y02P20/141

  Feedstock · CPC title

• C01B2203/1241

  Natural gas or methane · CPC title

• C01B2203/1052

  Nickel or cobalt catalysts · CPC title

• C01B2203/1017

  characterised by the form of the structure · CPC title

• C01B2203/0238

  the reforming step being a carbon dioxide reforming step · CPC title