Method and reactor for conversion of hydrocarbons
A reactor and method for the conversion of hydrocarbon gases utilizes a reactor ( 12, 312, 412, 512, 612 ) having a unique feed assembly with an original vortex combustion chamber ( 40, 340, 436, 536, 636 ), a diverging conduit ( 48, 348, 448, 548, 648 ), and a cylindrical reactor chamber ( 40, 340, 436, 536, 636 ). This design creates a compact reaction zone and an inwardly swirling fluid flow pattern of the feed gases to form a swirling gas mixture that passes through a diverging conduit ( 48, 348, 448, 548, 648 ). The feed streams can be introduced into the reactor ( 12, 312, 412, 512, 612 ) at any angle (radial, axial, or something between, or a combination of the above forms) with swirling flow components. The feed streams comprise preheated steam and hydrocarbons for cracking. This system provides conditions suitable for efficient cracking of hydrocarbons, such as ethane, to form olefins.
1. A reactor system for the conversion of hydrocarbons, the reactor system comprising:
a reactor vessel having a reactor wall that defines a reaction chamber, the reaction chamber having a central longitudinal axis, the reactor vessel having an upstream end and a downstream end;
a diverging conduit having an upstream end, a downstream end, and a circumferential wall expanding in width from the upstream end to the downstream end of the diverging conduit, the downstream end of the diverging conduit being in fluid communication with the reaction chamber of the reactor;
a feed assembly having an upstream end and a downstream end the downstream end of the feed assembly being operably coupled to the upstream end of the diverging conduit, with the central longitudinal axis passing through the feed assembly, the feed assembly comprising at least two flow inlets, wherein the two flow inlets provide a flow path for at least one each for heated gas and hydrocarbons, respectively;
wherein the flow inlets are configured to respectively receive the heated gas and hydrocarbon, and to cause the heated gas and hydrocarbon to mix together to form a swirling mixture as the heated gas and hydrocarbon flow from the feed assembly through the diverging conduit and into the reaction chamber;
wherein the flow inlets are configured to receive the heated gas preheated before entering the flow inlets;
wherein the reaction chamber is configured such that:
the heat required for cracking the hydrocarbon in the reaction chamber primarily comes from the thermal energy in the heated gas, and,
the reaction in the reaction chamber creates an exit stream comprising heated gas, hydrocarbon, and reaction products,
wherein at least one flow inlet causes its respective feed stream to enter the reactor in a direction that is approximately parallel to the central longitudinal axis, and at least one inlet flow space causes its respective feed stream to enter the reactor in a direction that is approximately perpendicular to the central longitudinal axis, with at least one feed stream having a tangential-to-radial or tangential-to-axial velocity component to form a swirling flow for mixing in the mixing feed streams.
2. The reactor system of claim 1 , wherein the feed assembly further comprises guide vanes, the guide vanes being movable to selected positions to provide selected tangential-to-radial or tangential-to-axial velocity ratios of feed streams for mixing in the mixing feed streams.
3. The reactor system of claim 1 , wherein the reaction chamber further comprises an outlet, through which the hydrocarbons and reaction products exit the reaction chamber.
4. The reactor system of claim 1 , wherein after the heated gas, hydrocarbon and reaction products exit the reaction chamber, the heated gas is separated from the rest of the exit stream.
5. The reactor system of claim 4 , wherein the separated heated gas is recycled back to a front of the reactor system.
6. The reactor system of claim 5 , further comprising a swirl atomizer configured to induce swirling in the mixing feed streams.
7. The reactor system of claim 1 , wherein the heated gas is preheated via renewable energy sources.
8. The reactor system of claim 1 , wherein at least one of the flow inlets is an atomizer, the atomizer providing a flow path for the hydrocarbon.
9. The reactor system of claim 8 , wherein the hydrocarbons coming in via the atomizer is naphtha, crude oil, pyoil from hydrocarbons, biomass, or plastic waste, or NGL in liquid phase.
10. The reactor system of claim 1 , wherein the reaction chamber has an outer wall, and wherein the selection and placement of the one or more flow inlets allows one to control the placement of the hydrocarbon with respect to the heated gas, the placement creating a cooled space in the interior of the reactor.
11. The reactor system of claim 10 , wherein the hydrocarbon first enters the reactor closest to the outer wall of the reactor, and then moves radially inward to interact with the heated gas.
12. The reactor system of claim 10 , wherein the hydrocarbon first enters the reactor closest to the central longitudinal axis of the reactor, and then moves radially outward to interact with the heated gas.
13. The reactor system of claim 1 , wherein the reactor system further comprises a converging conduit, the converging conduit having an upstream and downstream end, the central longitudinal axis passing through the converging conduit, the converging conduit being connected to the upstream end of the diverging conduit, and the upstream end of the feed assembly.
14. The reactor system of claim 13 , wherein the converging conduit and the diverging conduit together comprise a venturi.
15. The reactor system of claim 1 , wherein the heated gas is steam.
16. The reactor system of claim 1 , wherein the heated gas or the hydrocarbons contain impurities.