A catalytic reactor (40) comprises a plurality of sheets (42) defining flow channels (44) between them. Within each flow channel (44) is a foil (46) of corrugated material whose surfaces are coated with catalytic material apart from where they contact the sheets (44). At each end of the reactor (40)
A catalytic reactor (40) comprises a plurality of sheets (42) defining flow channels (44) between them. Within each flow channel (44) is a foil (46) of corrugated material whose surfaces are coated with catalytic material apart from where they contact the sheets (44). At each end of the reactor (40) are headers to supply gas mixtures to the flow channels (44), the headers communicating with adjacent channels being separate. The reactor (40) enables different gas mixtures to be supplied to adjacent channels (44), 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 sheets (42) separating the adjacent channels (44), from the exothermic reaction to the endothermic reaction. The reactor (40) may be used in a compact plant to perform steam/methane reforming, obtaining the necessary heat by catalytic methane combustion, and also for Fischer-Tropsch synthesis, so that the overall process involves conversion of methane to long-chain hydrocarbons.
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1. A catalytic reactor comprising a plurality of flat metal sheets arranged in a stack, said sheets being shaped for defining a plurality of side-by-side first fluid flow channels between first adjacent sheets and for defining a plurality of side-by-side second fluid flow channels between second adj
1. A catalytic reactor comprising a plurality of flat metal sheets arranged in a stack, said sheets being shaped for defining a plurality of side-by-side first fluid flow channels between first adjacent sheets and for defining a plurality of side-by-side second fluid flow channels between second adjacent sheets, said first flow channels alternating with said second flow channels in said stack for providing thermal contact between fluids in said first and second flow channels, said sheets being bonded together for ensuring fluid-tight channels, and such that the fluids in the first and the second fluid flow channels may differ in pressure,supply means for supplying fluids to said first and second flow channels, said supply means being such that different fluids can be supplied to said first and second fluid channels; anda permeable metal heat-transfer layer within at least each first flow channel, said metal heat-transfer layer being removable and incorporating on at least one surface thereof a catalytic coating, said catalytic coating optionally incorporating a ceramic layer, wherein said catalytic coating is provided only on those surfaces of said heat-transfer layer that do not come into contact with walls of said channel. 2. A catalytic reactor as claimed in claim 1 wherein said first and second flow channels are less than 8 mm deep in the direction normal to said adjacent metal sheets. 3. A catalytic reactor as claimed in claim 1 wherein, within each flow channel, said permeable metal heat-transfer layer incorporates a catalytic coating. 4. A catalytic reactor as claimed in claim 1, said reactor including a header, wherein said permeable metal heat-transfer layers are removable from its respective channel after removal of said header from said reactor. 5. A catalytic reactor as claimed in claim 1 wherein a catalyst metal is deposited directly onto said surface of said permeable metal heat-transfer layer. 6. A catalytic reactor as claimed in claim 1 incorporating electrical heating means for passing an electric current through said sheets. 7. A catalytic reactor as claimed in claim 1 for use in a process in which a liquid product is formed, wherein no catalyst is provided in those parts of said permeable metal heat-transfer layer that will be coated by said liquid product. 8. A plant for processing methane for producing longer chain hydrocarbons, said plant comprising a first catalytic reactor for performing steam/methane reforming;a second catalytic reactor for performing Fisher-Tropsch synthesis for creating a fluid mixture, each said catalytic reactor comprising a reactor as claimed in claim 1;transfer means for transferring products of said first catalytic reactor to said second catalytic reactor, said transfer means incorporating at least one heat exchanger for removing heat from said products; at least one compression means for increasing the pressure of said products; andmeans for condensing liquid components of said fluid mixture resulting from said Fisher-Tropsch synthesis. 9. A catalytic reactor comprising a plurality of metal sheets arranged as a stack, said sheets being shaped so as to define a plurality of side-by-side first flow channels between adjacent sheets and to define a plurality of side-by-side second flow channels between adjacent sheets, first flow channels alternating with second flow channels in the stack, and such that there is good thermal contact between fluids in the first and the second flow channels, the sheets being bonded to ensure fluid-tight channels, and such that the fluids in the first and the second fluid flow channels may differ in pressure; andsupply means for supplying fluids to said flow channels, said supply means enabling different fluids to be supplied to said first and second flow channels;wherein permeable metal heat-transfer layers are provided within said first flow channels, said metal heat-transfer layers being removable and incorporating a catalytic coating comprising a combustion catalyst for causing combustion of a gas mixture flowing in said first flow channels,wherein each first flow channel encloses one of said metal heat-transfer layers that incorporate a combustion catalyst,wherein each metal heat-transfer layer has a structure that is permeable to the gas flow along the first flow channel, andwherein said combustion catalyst in at least a first part of said channel is coated with a porous inert ceramic layer for restricting a reaction rate of said combustion. 10. A catalytic reactor as claimed in claim 9 wherein both said first and said second flow channels are less than 8 mm deep in the direction normal to said adjacent metal sheets. 11. A catalytic reactor as claimed in claim 9 wherein removable metal heat-transfer layers are provided in both said first and said second flow channels, each such metal heat transfer layer comprising a corrugated metal foil. 12. A catalytic reactor as claimed in claim 11 wherein in at least one of said flow channels the pitch of said corrugated foil varies along the length of said channel. 13. A catalytic reactor as claimed in claim 9 wherein the flow direction of said first flow channels is transverse to the flow direction of said second flow channels. 14. A catalytic reactor as claimed in claim 11 wherein the flow direction of the first flow channels is transverse to the flow direction of said second flow channels. 15. A catalytic reactor as claimed in claim 9 for performing methane/steam reforming, wherein removable metal heat-transfer layers are provided in both said first and said second flow channels, said permeable metal heat-transfer layers within said second flow channels incorporating a catalyst for methane/steam reforming. 16. A catalytic reactor comprising a plurality of flat metal sheets arranged in a stack, wherein said stack comprises a first sheet, a second sheet, and a third sheet, wherein said first sheet and said second sheet define a plurality of fluid tight first flow channels therebetween, wherein said second sheet and said third sheet define a plurality of fluid tight second flow channels therebetween, wherein said metal sheets arranged in the said stack are bonded together;headers for supplying fluids to said first and second flow channels, wherein said headers are capable of supplying different fluids to said first and second flow channels; anda permeable and removable metal heat-transfer layer within at least each first flow channel, wherein said metal heat-transfer layer comprises a catalytic coating on at least one surface thereof, wherein said catalytic coating is not provided on any surface of said heat-transfer layer that comes into contact with walls of the respective first flow channel. 17. A catalytic reactor as claimed in claim 16 wherein grooves in at least said first sheet define said first flow channels. 18. A catalytic reactor as claimed in claim 16 wherein said catalytic coating comprises a ceramic layer. 19. A catalytic reactor as claimed in claim 16 wherein both said first flow channels and said second flow channels are less than 8 mm deep in the direction normal to said metal sheets arranged in said stack. 20. A catalytic reactor as claimed in claim 16 for performing methane/steam reforming, wherein a permeable and removable heat-transfer layer is provided in said second flow channels, wherein said heat-transfer layer in the said first flow channels comprises a catalyst for combustion, wherein said heat-transfer layer in said second flow channels comprises a catalyst for methane/steam reforming.
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