Catalytic Reactors

Abstract

A compact catalytic reactor defining a multiplicity of alternately arranged first and second flow channels, for carrying first and second fluids, respectively. At least the first fluids undergo a chemical reaction. Each first flow channel contains a removable gas-permeable catalyst structure incorporating a metal foil substrate, said catalyst structure defining flow paths therethrough. The substrate comprises a stack of spaced-apart foils wherein the catalyst structure incorporates a multiplicity of resilient strips which are bent out from the foil substrate so as to project from the substrate and to support said catalyst structure resiliently spaced away from at least one adjacent wall of said channel. Each strip being connected to said catalyst structure only at an end or ends of said strip, and being integral with said foil.

1 - 10 . (canceled) 
     
     
         11 . A compact catalytic reactor defining a multiplicity of first and second flow channels arranged alternately in said reactor, for carrying first and second fluids, respectively, wherein at least said first fluids undergo a chemical reaction; wherein each first flow channel contains a removable gas-permeable catalyst structure incorporating a metal foil substrate, said catalyst structure defining flow paths therethrough; wherein said substrate comprises a stack of spaced-apart foils; wherein said catalyst structure incorporates a multiplicity of resilient strips which are bent out from the foil substrate so as to project from the substrate and to support said catalyst structure resiliently spaced away from at least one adjacent wall of said channel, each strip being connected to said catalyst structure only at an end or ends of said strip, and being integral with said foil; and
 wherein said catalyst structure, excluding said projecting strips, is of height less than a corresponding height of said channel by between 0.1 mm and about 1 mm.   
     
     
         12 . A catalytic reactor as claimed in  claim 11  wherein chemical reactions occur in both said first and said second flow channels, and wherein second flow channels contain removable gas-permeable catalyst structures that incorporate a metal foil substrate, and which define flow paths therethrough, wherein said catalyst structure incorporates a multiplicity of projecting resilient strips which support said catalyst structure spaced away from at least one adjacent wall of said channel, each strip being connected to said catalyst structure only at ends of said strip, and being integral with said foil. 
     
     
         13 . A catalytic reactor as claimed in  claim 11  wherein said catalyst structure comprises resilient strips projecting in opposite directions, so that said catalyst structure is spaced away from both opposed adjacent walls of said channel. 
     
     
         14 . A catalytic reactor as claimed in  claim 11  wherein said resilient strips comprise projecting lugs, attached to said foil at one end. 
     
     
         15 . A catalytic reactor as claimed in  claim 11  wherein said resilient strips comprise projecting curves, each being attached to said foil at both ends. 
     
     
         16 . A catalytic reactor as claimed in  claim 11  wherein the said substrate comprises a stack of spaced-apart foils in which at least some of the foils in the stack are spaced apart by resilient strips which are bent out from the foil substrate so as to project from the substrate. 
     
     
         17 . A catalytic reactor as claimed in  claim 11  wherein said first fluids undergo steam reforming. 
     
     
         18 . A catalytic reactor as claimed in  claim 11  wherein said first fluids undergo Fischer-Tropsch synthesis. 
     
     
         19 . A plant for processing natural gas for obtaining longer chain hydrocarbons, said plant comprising:
 a first reactor as defined by  claim 11 , wherein said first fluids undergo steam reforming, for reacting methane with steam for forming synthesis gas, and   a second reactor as defined by  claim 11 , wherein the second reactor is configured to be fed a stream from the first reactor;
 wherein said first fluids undergo Fischer-Tropsch synthesis for generating longer-chain hydrocarbons; 
 wherein the first reactor is a reforming reactor; and 
 wherein the second reactor is a synthesis reactor. 
   
     
     
         20 . A compact catalytic reactor defining a multiplicity of first and second flow channels arranged alternately in the reactor, for carrying first and second fluids, respectively, wherein at least said first fluids undergo a chemical reaction; wherein each first flow channel contains a removable gas-permeable catalyst structure incorporating a metal foil substrate, said catalyst structure defining flow paths therethrough; wherein said substrate comprises a stack of spaced-apart foils; wherein said catalyst structure incorporates a multiplicity of resilient strips which are bent out from the foil substrate so as to project from the substrate and to support said catalyst structure resiliently spaced away from at least one adjacent wall of said channel, each strip being connected to the catalyst structure only at an end or ends of the strip, and being integral with a said foil. 
     
     
         21 . A compact catalytic reactor as claimed in  claim 20  wherein the said substrate comprises a stack of spaced-apart foils in which at least some of the foils in the stack are spaced apart by resilient strips which are bent out from the foil substrate so as to project from the substrate. 
     
     
         22 . A compact catalytic reactor as claimed in  claim 21  wherein adjacent foils in the stack are spaced apart by resilient strips which are bent out from each adjacent foil, wherein said adjacent foils are secured to each other by means that interlock said resilient strips bent out from the adjacent foils.