Method for Carrying Out a Chemical Synthesis and Synthesis Reactor

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This patent describes a method and reactor design for carrying out chemical syntheses, especially those limited by reaction equilibrium. It features a multi-stage process in which reactants are sequentially passed through multiple reaction chambers operating at decreasing pressures. At each stage, the unreacted reactant and product are separated, with the unreacted material entering the next chamber. Heat pipes are used between chambers to efficiently exchange heat and maintain nearly uniform temperature, allowing almost complete conversion of reactants with improved energy efficiency over conventional systems.

Use CasesContent extracted from patent full text and abstract with AI.

• Industrial production of chemicals such as methanol and ammonia, where equilibrium-limited reactions occur
• Production of synthesis gases (syngas) or downstream chemical processing
• Applications in refineries or petrochemical plants for improving conversion and reducing recirculation loads
• Any large-scale heterogeneous catalysis operation with incomplete single-pass conversion, especially in gas or slurry phase reactors
• Upgrade for existing chemical plant reactors to increase productivity and reduce energy costs

BenefitsContent extracted from patent full text and abstract with AI.

• Substantially higher conversion rates of reactants compared to conventional single-stage or recycle reactors
• Reduces the need for large-scale gas recirculation and associated equipment (e.g., compressors), lowering operational costs
• Improves energy efficiency through use of heat pipes for stage-to-stage heat exchange and isothermal operation
• Can decrease reactor size for a given throughput, leading to potential capital cost savings
• Flexible design: applicable to liquid phase (slurry), fixed-bed, or fluidized-bed (gas phase) catalysis
• Mitigates buildup of inert gases and impurities commonly caused by recirculation in traditional processes
• Allows for improved process control and potentially safer reactor operation due to lower pressures in downstream stages

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Patent Abstract

The invention relates to a method for carrying out a chemical synthesis, comprising the following steps: - introducing at least one synthesis reactant (2) into a reaction chamber (4), in which a pressure p1 prevails, - producing at least one synthesis product (6) in the reaction chamber (4), - discharging the synthesis product (6) and an unreacted synthesis reactant (8) from the reaction chamber (4), - separating the synthesis product (6) from the unreacted synthesis reactant (8), and - introducing the unreacted synthesis reactant (8) into a second reaction chamber (10), in which a pressure p2 prevails which is lower than the pressure p1.