초록 ▼

The present invention provides a process for the manufacture of acetylene and other higher hydrocarbons from methane feed using a reverse-flow reactor system, wherein the reactor system includes (i) a first reactor and (ii) a second reactor, the first and second reactors oriented in a series relatio

The present invention provides a process for the manufacture of acetylene and other higher hydrocarbons from methane feed using a reverse-flow reactor system, wherein the reactor system includes (i) a first reactor and (ii) a second reactor, the first and second reactors oriented in a series relationship with respect to each other, the process comprising supplying each of first and second reactant through separate channels in the first reactor bed of a reverse-flow reactor such that both of the first and second reactants serve to quench the first reactor bed, without the first and second reactants substantially reacting with each other until reaching the core of the reactor system.

대표청구항 ▼

1. A cyclic reverse flow reactor system for the manufacture of acetylene from methane feed, wherein the reactor system comprises: (i) a first reactor comprising a first end and a second end;(ii) a second reactor comprising primary end and a secondary end, the first and second reactors oriented in a

1. A cyclic reverse flow reactor system for the manufacture of acetylene from methane feed, wherein the reactor system comprises: (i) a first reactor comprising a first end and a second end;(ii) a second reactor comprising primary end and a secondary end, the first and second reactors oriented in a series flow path relationship with respect to each other such that the secondary end of the second reactor is proximate the second end of the first reactor; wherein the first reactor further comprises;(a) a first channel to supply at least a first reactant from the first end of the first reactor to the second end of the first reactor;(b) a second channel to supply at least a second reactant from the first end of the first reactor to the second end of the first reactor; and(c) a product removal line to remove at least one of methane and a produced acetylene from a first end of the first reactor;wherein the second reactor further comprises;(i) a flue gas removal line to remove at least a portion of a heated reaction product produced from mixing and reacting the first and second reaction products; and(ii) a methane feed line to feed methane to the primary end of the second reactor. 2. The reactor system of claim 1, wherein the reactor system is configured such that during a regeneration step to heat the reactor system, at least a majority of the stoichiometrically reactable first reactant and second reactant do not exothermically react with each other in the first reactor. 3. The reactor system of claim 1, further comprising a mixer situated intermediate the first reactor and second reactor to mix the first reactant with the second reactant. 4. The reactor system of claim 3, wherein the mixer further comprises at least one mixer segment, wherein each segment receives at least a portion of the first and second reactant to mix the at least a portion of the first and second reactant in the respective segment. 5. The reactor system of claim 3, wherein the mixer is constructed from material able to withstand temperatures in excess of about 1500° C. 6. The reactor system of claim 3, wherein the mixer is constructed from material able to withstand temperatures in excess of about 1700° C. 7. The reactor system of claim 3, wherein the mixer comprises a ceramic. 8. The reactor system of claim 1, wherein the first reactor has a void volume A, and the second reactor has a void volume B, and the mixer has a void volume C, whereby void volume C is less than or equal to about twenty percent of the total of void volume A plus void volume B plus void volume C. 9. The reactor system of claim 1, wherein the first reactor comprises at least two layers of reactor bed material and the first channel comprises at least one of the at least two layers and the second channel comprises another of the at least two layers. 10. The reactor system of claim 9, wherein a reactant flow path through each of the at least two layers is substantially not in fluid communication with a flow path through an immediately adjacent layer. 11. The reactor system of claim 1, further comprising at least one flow restrictor to control flow into at least one of the at least two layers. 12. The reactor system of claim 11, wherein the flow restrictor comprises at least one of an actuated valve and a passively responsive valve. 13. The reactor system of claim 11, wherein at least one of the flow restrictors is positioned on an end face on a first end of the first reactor. 14. The reactor system of claim 1, further comprising a methane supply line to supply methane to the primary end of the second reactor for conversion to acetylene in the second reactor. 15. The reactor system of claim 1, further comprising a hydrogen supply line to supply hydrogen to the primary end of the second reactor to moderate the conversion of the methane. 16. The reactor system of claim 1, further comprising a fuel gas supply line to supply a fuel gas to one of the first channel and the second channel in the first reactor. 17. The reactor system of claim 1, further comprising a second reactant supply line to supply a second reactant to react with the first reactant. 18. The reactor system of claim 1, wherein the second channel is in fluid communication with the second reactant which comprises oxygen. 19. The reactor system of claim 1, wherein the first channel is in fluid communication with the first reactant which comprises a combustible fuel and wherein the second channel is in fluid communication with the second reactant which comprises air. 20. The reactor system of claim 1, wherein the second channel is in fluid communication with the second reactant which comprises at least one of (i) a noncombustible gas, and (ii) a mixture of combustible and noncombustible gases. 21. The reactor system of claim 1, wherein the second channel is in fluid communication with the second reactant which comprises an exhaust gas recycle (EGR). 22. The reactor system of claim 1, wherein the first reactor comprises a bed packing whereby at least one of the first channel and the second channel include an average wetted surface area per unit volume that ranges from about 50 ft−1 to about 3000 ft−1. 23. The reactor system of claim 1, wherein the first reactor comprises a bed packing whereby at least one of the first channel and the second channel include an average volumetric heat transfer coefficient of greater than or equal to 0.02 cal/cm3s°C. 24. The reactor system of claim 1, wherein the system comprises at least one of a valve and a flow restrictor to prevent flow of one of the first and second reactants into one of the first channel and second channel of the reactor. 25. The reactor system of claim 24, wherein the flow restrictor comprises at least one of an actuated valve, a check valve, and a louver-type flow valve. 26. The reactor system of claim 1, wherein at least one of the first channel and the second channel comprises a flow path through a porous media.