US 12,281,011 B1
Reactor for conversion of hydrocarbons and oxygenates to syngas and hydrogen
Timothy Griffith Fogarty, Prospect, KY (US); Jeffrey Baker Harrison, Louisville, KY (US); Devendra Pakhare, Louisville, KY (US); Timothy David Appleberry, Louisville, KY (US); and Joshua Aaron Gubitz, Louisville, KY (US)
Assigned to PCC HYDROGEN INC., Louisville, KY (US)
Filed by PCC HYDROGEN INC., Louisville, KY (US)
Filed on Jul. 3, 2024, as Appl. No. 18/764,094.
Application 18/764,094 is a continuation of application No. 18/486,744, filed on Oct. 13, 2023, granted, now 12,060,269.
Int. Cl. C01B 3/32 (2006.01); B01J 12/00 (2006.01); B01J 19/24 (2006.01); B01J 35/56 (2024.01); C01B 3/38 (2006.01); C01B 3/40 (2006.01); C01B 3/48 (2006.01); C01B 3/56 (2006.01)
CPC C01B 3/326 (2013.01) [B01J 12/007 (2013.01); B01J 19/242 (2013.01); B01J 35/56 (2024.01); C01B 3/382 (2013.01); C01B 3/40 (2013.01); C01B 3/48 (2013.01); C01B 3/56 (2013.01); C01B 2203/0233 (2013.01); C01B 2203/0261 (2013.01); C01B 2203/0283 (2013.01); C01B 2203/043 (2013.01); C01B 2203/085 (2013.01); C01B 2203/0883 (2013.01); C01B 2203/1029 (2013.01); C01B 2203/1229 (2013.01); C01B 2203/1288 (2013.01); C01B 2203/142 (2013.01)] 30 Claims
OG exemplary drawing
 
1. A process for converting one or more gaseous reactants to one or more gaseous reaction products, comprising:
impinging the one or more gaseous reactants on a foam body having a conversion catalyst thereon and/or therein in a non-autothermal adiabatic contacting zone to effect chemical conversion reaction catalyzed by the conversion catalyst on and/or in the foam body as at least part of chemical reaction performed in the non-autothermal adiabatic contacting zone producing the one or more gaseous reaction products; and
discharging the one or more gaseous reaction products from the non-autothermal adiabatic contacting zone,
wherein the one or more gaseous reactants are impinged on an inlet surface of the foam body having the conversion catalyst thereon and/or therein, at an angle α with respect to a central axis of the non-autothermal adiabatic contacting zone, for subsequent flow through the foam body, the angle being in a range of 10°<α<75°, and
wherein the chemical conversion reaction catalyzed by the conversion catalyst on and/or in the foam body comprises an exothermic catalytic partial oxidation reaction as a first stage of the chemical reaction performed in the non-autothermal adiabatic contacting zone, driving an endothermic reaction as a second stage of the chemical reaction performed in the non-autothermal adiabatic contacting zone.