Tubular Reactor and Method for Operating a Tubular Reactor

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The patent describes a plug flow tube reactor and its operation for converting hydrogen and carbon dioxide into methane and water using at least three reaction zones, each with its own catalyst and carefully managed temperature profile. Each zone is insulated to allow adiabatic (no heat loss) reactions, and between at least two zones, cooling fluid (preferably water) can be dynamically introduced. This arrangement allows the reactor to flexibly and efficiently produce methane even when hydrogen supply fluctuates, such as with hydrogen produced from water electrolysis powered by variable renewable energy sources.

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• Power-to-gas systems for storing surplus renewable electricity by converting it to synthetic methane.
• Integration with existing natural gas infrastructure to inject renewable methane generated from fluctuating hydrogen supply.
• Decentralized or flexible chemical plants producing synthetic fuels.
• Industrial processes requiring dynamically operated methanation units, such as hydrogen storage buffer elimination.
• Transport and mobility sectors using synthetic methane as fuel for vehicles.
• Biogas upgrading through methanation of CO2 using renewable hydrogen.

BenefitsContent extracted from patent full text and abstract with AI.

• Allows highly flexible and dynamic operation adapting to fluctuations in hydrogen supply, ideal for renewable energy integration.
• Enables direct injection of synthetic methane into existing natural gas grids without complex gas purification.
• Reduces or eliminates the need for expensive, large hydrogen storage buffers.
• Improves energy efficiency by controlling reaction temperatures precisely and recovering heat within the process.
• Prevents catalyst and reactor material degradation by avoiding temperature extremes, extending system life.
• Supports the production of low-carbon or carbon-neutral fuels, aiding decarbonization efforts.

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Patent Abstract

The invention relates to a plug flow reactor and a method for operating a plug flow reactor for converting hydrogen into methane, comprising at least three reaction zones. Each reaction zone has a catalyst. A first reaction zone has a first temperature in a first temperature range, a second reaction zone has a second temperature in a second temperature range, and a third reaction zone has a third temperature in a third temperature range. Each reaction zone is insulated such that the methanation can be carried out adiabatically within one reaction zone. A supply device for a cooling fluid is arranged between at least two adjacent reaction zones. The aforementioned arrangement of the reaction zones in combination with the supply device for a cooling fluid allows a dynamic operation of the plug flow reactor on the basis of the quantity of the reactant gas.