HK40050971A

HK40050971A - Method and reactor for producing one or more products

Info

Publication number: HK40050971A
Application number: HK62021040561.4A
Authority: HK
Inventors: 约翰·B·辛基二世; 蒂莫西·J·埃尔德; 肯尼斯·W·克拉茨舒玛; 克里斯托弗·E·J·里德
Original assignee: 埃科纳能源公司
Priority date: 2018-12-10
Filing date: 2019-12-09
Publication date: 2021-12-31

Description

Method and reactor for producing one or more products

Technical Field

The present disclosure relates to a process and associated reactor for producing one or more products, for example, by cracking a feed gas, such as natural gas.

Background

Natural gas (CH)₄) By chemical cracking is meant the separation of natural gas into its carbon (C) and hydrogen (H)₂) The composition of (1). Conventional methods of hydrogen generation, such as Steam Methane Reforming (SMR), result in large amounts of diluted CO₂Venting, which may require expensive post-reforming purification for sequestration. As a result, the SMR produces one ton of H₂About 8 to 10 tons of CO are produced₂. Introducing CO₂Clean-up addition to the SMR flue gas stream is typically costly unless the penalty for carbon dioxide emissions increases to a critical point.

There are other methods of thermal decomposition to produce hydrogen and solid carbon, such as thermal and liquid metal pyrolysis and plasma pyrolysis. These processes are generally tailored to maximize the production of solid carbon for the relevant carbon market and are widely used in these industries.

Thermal cracking of natural gas is generally a constant pressure, steady flow process whereby the natural gas is heated until it reaches the temperature required to begin the formation of hydrogen and carbon. At this time, the temperature was maintained for a certain time to complete the equilibrium reaction. Assuming a constant pressure of 1ATM, the time required for methane conversion decreases with increasing temperature (as shown in fig. 1-plots obtained from kinetic models of homogeneous thermal decomposition of methane and ethane, maps obtained from kinetic models of homogeneous thermal decomposition of methane and ethane, Maryan younesis-Sinaki, Edgar a, Matida, Feridun Hammullahpur, carreton University, Department of Mechanical and Aerospace Engineering, 1125 Colonel By Drive, Ottawa, ON K1S 5B6, Canada, the entire contents of which are incorporated herein By reference).

In such a steady flow reactor, the carbon build-up tends to be lowBuild up towards the surface of the reactor and eventually become so thick as to impair reactor performance. Mechanical scraping processes or burning off carbon from the surface by introducing air into the reactor are two common means of cleaning the reactor. Mechanical scraping is difficult to perform and may not remove hard carbon deposits. Combustion of carbon with air produces large quantities of CO₂Discharge, which is undesirable. Therefore, it is highly desirable not to form carbon on the surface first, and to send the produced carbon to downstream processes.

In addition, a shorter reaction time is required to reduce the size of the reactor, but this requires very expensive high temperatures and foreign materials. To try and overcome this, a catalyst having the effect of lowering the reaction temperature was added to the reactor. However, carbon build-up now also occurs on the surface of the catalyst, which over time becomes deactivated and requires a reactivation process or is replaced. Both of these options are expensive and add to the complexity of the process.

Liquid medium reactors, such as liquid metal reactors, involve a thermal process whereby natural gas is bubbled through a column of a high temperature liquid, such as a liquid metal or salt. Since this is a constant pressure and flow process, the same temperature time-varying reaction rates as described above are applied. The benefit of this process is that since the hydrogen bubbles produced exit the top of the reactor column and the carbon floats on the surface of the liquid medium, it can theoretically be skimmed off, simplifying the separation of hydrogen and carbon. In some embodiments, a liquid metal alloy has been identified that provides a catalytic effect and reduces the reaction temperature. However, in all cases, carbon build-up at the top of the reactor remains an issue, and the use of molten media adds complexity, material challenges, and cost to the reactor.

For most thermal processes, the energy required to heat the reactor and sustain the process is typically provided by burning some excess natural gas with air. The flue gas converts CO₂Released into the atmosphere and contribute to global warming. In some cases, excess carbon buildup and/or hydrogen may also be used to provide heat of reaction.

The plasma reactor passes natural gas at a constant pressure through a high temperature plasma generated by electricity. The plasma may be generated by using, for example, an electrode or a microwave. Carbon build-up is still a problem in these reactors, but is less than in thermal reactors because the high temperature plasma is confined to a very small area. Unlike thermal reactors, plasma reactors rely solely on electricity as an energy input. Compared to thermal systems, the cost of electricity for input energy is much higher than that of natural gas, and therefore the resulting production cost of hydrogen and methane is much higher.

Accordingly, there is a need in the art for a natural gas cracking process that uses thermal energy with lower capital costs and less subject to carbon buildup problems.

Disclosure of Invention

In general, the present disclosure relates to (but is not limited to) cracking natural gas into carbon (C) and hydrogen (H) using dynamic gas compression and mixing to produce the pressure and temperature required to thermally decompose natural gas₂) The component (c). The goal of the process is to optimize the process for hydrogen production and recover solid carbon as the second value stream while minimizing carbon greenhouse emissions. When paired with a Direct Carbon Fuel Cell (DCFC), the carbon product can be used to generate electricity and pure product stream CO₂Suitable for sealing (see figure 2). The result is a low cost "clean" hydrogen gas.

According to a first aspect of the present disclosure there is provided a method of producing one or more products comprising: introducing a feed gas into the mixing chamber, wherein the feed gas comprises one or more gases; introducing a combustible gas into the combustion chamber, wherein the combustible gas comprises one or more gases; and thereafter, igniting the combustible gas so as to cause the combustible gas to flow into the mixing chamber via the one or more fluid flow paths between the combustion chamber and the mixing chamber and to mix with the feed gas, wherein energy is transferred from the combustible gas to the feed gas to produce the one or more products.

The feed gas and combustible gas may be introduced in such a way that the feed gas is substantially not mixed with the combustible gas, or undergoes little or negligible mixing, prior to ignition.

The method may further comprise stopping further production of the one or more products.

The method may further comprise preheating the feed gas prior to introducing the feed gas into the mixing chamber.

The method may further comprise preheating the combustible gas prior to introducing the combustible gas into the combustion chamber.

The ratio of the volume of the mixing chamber to the volume of the combustion chamber may be less than or equal to about 10: 1.

The ratio of the length of the mixing chamber to the diameter of the mixing chamber may be less than or equal to about 30: 1.

The feed gas may comprise natural gas. The feed gas may comprise a mixture of natural gas and recycle gas. The recycle gas may comprise one or more of: natural gas; hydrogen gas; carbon monoxide; and carbon dioxide.

The combustible gas may comprise an oxidant. The oxidant may include one or more of oxygen and air. The combustible gas may comprise CH₄And O₂A mixture of (a). The combustible gas may comprise a mixture of recycle gas and oxidant. The recycle gas may comprise one or more of: natural gas; hydrogen gas; carbon monoxide; and carbon dioxide.

The combustible gas may be introduced into the combustion chamber at the same time that the raw gas is introduced into the mixing chamber.

The combustible gas may be introduced into the combustion chamber at a pressure equal to the pressure at which the feed gas is introduced into the mixing chamber.

The one or more products may include one or more of hydrogen and carbon.

The one or more products may include one or more of hydrogen and carbon monoxide.

The one or more products may include one or more of hydrogen, nitrogen, and carbon. Hydrogen and nitrogen may be used to produce ammonia.

Stopping further production of the one or more products may include reducing the pressure within the mixing chamber. The pressure in the mixing chamber may be reduced sufficiently rapidly, for example by at least 50% in less than 1 second, to inhibit carbon deposition in the mixing chamber.

The pressure wave generated by the combustion of the combustible gas can suppress the carbon deposition of the mixing chamber.

Energy can be transferred from the combustible gas to the feed gas via gas dynamic compression and mixing.

After ignition but before the combustible gas is mixed with the feed gas, the temperature in the combustion chamber may be about 90ATM and-3,700K, for example as pure O₂As an oxidant and the recycle gas as a combustible gas.

After mixing the combustible gas with the feed gas, and before producing the one or more products, at least a portion of the mixture of feed gas and combustible gas may be transferred to the third chamber. Thus, the combustion chamber and the mixing chamber may be replenished with fresh combustible gas and feed gas while the user waits for one or more products to be produced in the third chamber.

In another aspect of the present disclosure, there is provided a raw material gas reactor including: a mixing chamber; a combustion chamber; a valve for controlling the flow of gases into and out of the mixing chamber and the combustion chamber; an igniter; and one or more controllers configured to perform a method comprising: controlling a valve to introduce a feed gas into a mixing chamber, wherein the feed gas comprises one or more gases; controlling a valve to introduce a combustible gas into the combustion chamber, wherein the combustible gas comprises one or more gases; thereafter, the igniter is controlled to ignite the combustible gas so as to cause the combustible gas to flow into the mixing chamber via the one or more fluid flow paths between the combustion chamber and the mixing chamber and to mix with the feed gas, wherein energy is transferred from the combustible gas to the feed gas to produce the one or more products.

The raw material gas and the combustible gas may be introduced in such a manner that the raw material gas is not substantially mixed with the combustible gas.

The method may further comprise controlling the valve to stop further production of the one or more products.

The combustion chamber may be located within the mixing chamber. The combustion chamber may be offset from a longitudinal axis of the mixing chamber.

The combustion chamber may be located outside the mixing chamber.

The combustion chamber may include one or more apertures formed therein.

The feed gas reactor may include any of the features described in connection with the first aspect of the invention.

In another aspect of the present disclosure, there is provided a raw material gas reactor including: a mixing chamber; a combustion chamber comprising one or more apertures formed therein, wherein the one or more apertures provide one or more fluid flow paths from the combustion chamber to the mixing chamber; a valve for controlling the flow of gases into and out of the mixing chamber and the combustion chamber; and an igniter.

Controlling the valves may include controlling the opening and/or closing of individual valves. Alternatively or additionally, the control valve may comprise a valve that rotates relative to the reactor (e.g., using a motor).

In another aspect of the present disclosure, there is provided a system comprising: a plurality of feed reactors, each reactor comprising: a mixing chamber; a combustion chamber; and an igniter; a valve for controlling the flow of gases into and out of the mixing chamber and the combustion chamber; and one or more controllers configured to perform a method comprising, for each reactor: controlling a valve to introduce a feed gas into the mixing chamber, wherein the feed gas comprises one or more gases; controlling a valve to introduce a combustible gas into the combustion chamber, wherein the feed gas comprises one or more gases; thereafter, the igniter is controlled to ignite the combustible gas so as to cause the combustible gas to flow into the mixing chamber via the one or more fluid flow paths between the combustion chamber and the mixing chamber and mix with the feedstock gas, wherein energy is transferred from the combustible gas to the feedstock gas and thereby produce one or more products, wherein, for a given reactor, the method is performed out of sync with at least one other reactor of the plurality of reactors.

For each reactor, the feed gas and the combustible gas may be introduced in such a manner that the feed gas is not substantially mixed with the combustible gas.

For each reactor, the method may further comprise controlling a valve to stop further production of the one or more products.

The plurality of reactors may be arranged radially about a central axis, and the system may further comprise a spinner configured to: rotating a plurality of reactors about a central axis relative to a valve assembly comprising a valve; or rotating a valve assembly including a valve about a central axis relative to a plurality of reactors. Thus, the valve assembly may rotate when the reactor is stationary, or the valve assembly may be stationary when the reactor is rotating. In some embodiments, the valve assembly and the reactor may even rotate simultaneously.

The system may comprise any of the features described in connection with the first aspect of the invention.

In another aspect of the present disclosure, there is provided a system comprising: one or more of any of the above reactors; and one or more fuel cells coupled to the one or more reactors and configured to receive carbon produced by mixing the combustible gas with the feed gas.

Drawings

Embodiments of the present disclosure will now be described in detail with reference to the accompanying drawings, in which:

FIG. 1 is a graph of the mole fraction of hydrogen produced from methane at a pressure of 1 atmosphere at different temperatures and time constants;

fig. 2 illustrates the combination of natural gas dissociation and a carbon fuel cell for the production of hydrogen, electricity and pure carbon dioxide according to an embodiment of the present disclosure;

FIG. 3 is a schematic diagram of a system for cracking natural gas according to an embodiment of the present disclosure;

FIGS. 4A and 4B illustrate different arrangements of mixing and combustion chambers according to embodiments of the invention;

FIG. 5 is a schematic illustration of a method of cracking natural gas according to an embodiment of the disclosure;

FIG. 6 illustrates different configurations of a system including asynchronously operated bundled reactors, according to an embodiment of the invention;

FIG. 7 illustrates a bundled reactor rotating around a fixed valve in accordance with an embodiment of the disclosure;

FIG. 8 is a schematic block diagram of a combustion chamber and a mixing chamber for providing mixing of a raw gas with a combustible gas, the combustible gas and raw gas mixture being directed to a third chamber, and one or more products being produced from the mixture in the third chamber, according to an embodiment of the disclosure;

FIG. 9 is a schematic block diagram of a combustion chamber and a mixing chamber for providing mixing of a feed gas and a combustible gas, and wherein one or more products are produced from the mixture, according to an embodiment of the disclosure;

FIG. 10 is a schematic block diagram of a combustion chamber and a mixing chamber for providing mixing of a feed gas with a combustible gas, and wherein one or more products are produced from the mixture, and wherein recycled gas is used to provide heat energy for the process, according to an embodiment of the present disclosure;

FIG. 11 is a schematic view of a combustion chamber located within a mixing chamber according to an embodiment of the present invention;

FIG. 12 is a schematic view of a combustion chamber located outside of a mixing chamber according to an embodiment of the present invention;

FIG. 13 illustrates a combustion chamber disposed within a mixing chamber, according to an embodiment of the present disclosure; and is

FIG. 14 shows a multiple reactor bundle with fixed reactors and rotating valves according to an embodiment of the present disclosure.

Detailed Description

The present disclosure seeks to provide improved processes and reactors for producing one or more products. While various embodiments of the present invention are described below, the present invention is not limited to these embodiments, and variations of these embodiments may well fall within the scope of the present invention, which is to be limited only by the following claims.

The terms "a" or "an" when used in conjunction with the terms "comprising" or "including" in the claims and/or the specification can mean "one," but it is also consistent with the meaning of "one or more," "at least one," and "one or more than one," unless the content clearly dictates otherwise. Similarly, the word "another" may mean at least a second or more, unless the content clearly dictates otherwise.

The terms "coupled," "coupled," or "connected," as used herein, may have a number of different meanings depending on the context in which the terms are used. For example, the terms coupled, or connected may have a mechanical or electrical meaning. For example, as used herein, the terms coupled, or connected may indicate that two elements or devices are connected to each other directly or via one or more intermediate elements or devices via electrical, or mechanical elements, depending on the particular context. The term "and/or" as used herein when used in association with a list of items refers to any one or more of the items comprising the list.

As used herein, reference to "about" or "approximately" a number or "substantially" is equal to a number means within +/-10% of the number.

In general, in accordance with embodiments of the present disclosure, an ultra-rich pulse pyrolysis process for producing a hydrogen-rich gas and/or carbon product from a natural gas feedstock is described. For large scale hydrogen production, the process can compete with SMR.

In accordance with an embodiment of the present disclosure, a pulsed reaction process using an unstable, constant volume is described to produce hydrogen and carbon products from a natural gas based feedstock. The separate chambers of combustible gas and oxidant provide the energy for the reaction and are transferred directly to the feedstock mixing chamber by gas dynamic compression and rapid mixing thermal energy exchange via direct contact. In the following discussion, air is used as the oxidant; however, other oxidants, such as pure oxygen, may be used in the process. Further, the raw gas and the combustible gas may include the same gas or gas mixture or may include different gases or gas mixtures. In some embodiments, the combustible gas may include a recirculated gas mixture.

The reactor includes a mixing chamber and a combustion chamber. The chambers are connected via channels that are always open. In some embodiments, the reactor comprises a perforated tube (combustion chamber) within a larger solid tube (mixing chamber); see fig. 3 and 4A. In other embodiments, the combustion chamber may be external to the mixing chamber (as shown in fig. 4B). An external valve provides the feedstock, oxidant and combustible gas (shown as CH)₄) As well as vented hydrogen, carbon, and other gases produced during the reaction.

Turning to fig. 5, at the beginning of a cycle, the mixing chamber is filled with the product of the previous reaction cycle. The mixing chamber is filled with a mixture of the raw reaction products plus a portion of the combustion reaction products. The combustion chamber is primarily filled with products of the combustion reaction. At 500, fresh feedstock and possibly some recycled product gas are introduced into the mixing chamber to displace the product of the previous cycle from the end of the mixing chamber. Simultaneously, a combustible gas/air mixture is introduced into the combustion chamber, thereby expelling the combustion products from the end of the combustion chamber. At 502, all inlet and outlet valves are closed, creating a closed volume. The gases in the combustion chamber are then ignited at 504, resulting in an increase in pressure and temperature within the combustion chamber. At 506, passages between the combustion chamber and the mixing chamber allow the combustible gas products to enter the mixing chamber, thereby compressing the feed gases and increasing their pressure and temperature. In addition, the hot combustion chamber gas product mixes with the feed gas and thereby transfers its thermal energy to the feed gas, thereby further increasing its temperature. The temperature and pressure of the resulting raw material gas cause a reaction to occur. At 508, the reaction is allowed to proceed for a period of time to complete the desired reaction and develop the desired product. At 510, the pressure within the mixing chamber is rapidly reduced by releasing the product to an external volume (not shown). The combustion product gases remaining in the combustion chamber may be exhausted with the mixing chamber gases or separately through dedicated ports. Reducing the pressure in the mixing chamber reduces the temperature and stops or quenches the reaction. Rapid depressurization and expansion also have the desired effect of removing solid reaction products (such as carbon) from the reactor walls. In addition, the pressure waves generated by combustion can strip carbon deposits from the reactor walls.

If the raw material and combustible gas are premixed, the mixture may not ignite because it is too rich. Thus, the mixing chamber and the combustion chamber are distinct and separate prior to ignition, such that no or preferably very little mixing occurs between the raw gas and the combustible gas.

Multiple reactor systems may be bundled together and operated slightly out of synchronization with each other to produce a continuous flow into and out of the reactor systems. The valve may be stationary or rotating, as shown in FIG. 6. In some embodiments, the reactor may be rotated and the valves may be held stationary (see fig. 7, modified from fig. 2 of the wave rotor design method, with three steps including experimental verification, Chan Shining et al, Journal of Gas Turbines and Power Engineering (Journal of Engineering for Gas Turbines and Power), 12 months 2017, the entire contents of which are incorporated herein by reference).

Various parameters may be adjusted to enable the reactor to operate efficiently. The feed gas may be preheated to a temperature just below the temperature at which it begins to react prior to introduction into the mixing chamber. Typical temperatures will range from 600K to 1000K depending on the feed composition and operating pressure.

Furthermore, it is also possible to preheat the incoming combustible gas/oxidant mixture before it enters the combustion chamber. Typical temperatures will be in the range of 400K to 700K, depending on the combustible gas used. Preheating the combustible gas/oxidant mixture may improve the efficiency of the process such that more combustion energy is transferred to the reactants rather than being used to heat the combustion products.

The volume ratio between the mixing chamber and the combustion chamber should be set such that the correct amount of energy contained in the combustion chamber is provided to the mixing chamber to produce the desired product. There should also be sufficient combustible gas product entering the mixing chamber to provide effective mixing. A volume ratio of less than 10: 1 is generally desirable. When using air as the oxidant, nitrogen may be beneficial as a non-reactive gas to improve the lower volume ratio and increase mixing. When pure oxygen is used as the oxidant, another gas (such as CO)₂) The same benefits as nitrogen in air as the oxidant can be provided. Additional CO₂Introduction into the combustible gas mixture may result in greater solid carbon production.

The aspect ratio is important to obtain an efficient energy transfer from the combustion chamber to the mixing chamber. Short, large diameter reactors tend to have poor mixing, while long, narrow reactors present challenges in introducing feedstock and combustible gases into the reactor along its length. An aspect ratio of less than 30: 1 is generally desirable.

According to some embodiments, the reactor uses methane (or natural gas) as the feed gas in addition to some recycled product gas, and uses the recycled gas/oxidant mixture as the combustible gas. The reactor can be designed and operated to maximize the production of hydrogen and solid carbon in the reaction product stream. The reactor may include a combustion chamber within the mixing chamber, the combustion chamber being a perforated tube. The perforated combustion chamber may be offset from the center of the mixing chamber and incorporate the walls of the mixing chamber to provide structural integrity and support, as shown in fig. 13. The mixing chamber/combustion chamber volume ratio may be less than or equal to 10: 1 and the length to diameter ratio may be 10: 1. In some embodiments, the mixing chamber/combustion chamber volume ratio may be about 6: 1, and in some embodiments, the mixing chamber/combustion chamber volume ratio may be about 3.5: 1.

As shown in fig. 14, multiple reactor tubes may be arranged with external rotary valves to provide flow and sequencing of all raw materials, combustible gases and reaction products. Separate ports may exhaust combustion products of the combustion chamber.

The reactor may be operated at a sufficiently high pressure so that the resulting hydrogen can be purified using standard pressure swing absorption techniques. According to some embodiments, the product gas (such as, unreacted methane (CH)₄) Carbon monoxide (CO) and some hydrogen) and mixed with more methane to produce a feed gas mixture to the reactor. The combustible gas mixture comprises in addition (in the case of an air-blown reactor) from CO₂Removing CO removed by the system₂A recycled gas mixture other than oxygen, and pure oxygen. In some embodiments, in addition to CH₄CO and H₂In addition, the recirculated gas mixture flowing to both the combustion chamber and the mixing chamber also contains CO₂. The feed gas mixture and the combustible gas mixture are preheated to-900K and-600K, respectively, from the thermal energy recovered from the reactor product stream via the multi-stream heat exchanger. In an alternative embodiment, a mixing chamber/combustion chamber volume ratio of 3.5: 1, a methane (or natural gas)/air mixture is used for these combustible gases.

A detailed description of embodiments of the present disclosure will now be provided.

Referring to FIG. 8, the combustible gas 10 and oxidant gas 20 enter the combustion mixture conditioning and control system 30, which conditions the combustible gas mixture 31 to the correct temperature and pressure required by the chamber 60. The feed gas 40 and the recycle gas mixture 91 enter the feed mixture conditioning and control system 50, which conditions the feed mixture 51 to the correct temperature and pressure required by the chamber 60. In some embodiments, the recycle gas mixture is not available and only the feed gas 40 enters the feed mixture conditioning and control system 50.

Chamber 60 is a constant volume device that uses the combustion energy from the conditioned combustible gas mixture 31 to raise the pressure and temperature of the conditioned feedstock mixture 51 to reaction preparation levels. A combustion product gas mixture 67 comprising primarily the combustion products of combusting the conditioned combustible gas mixture 31 may be discharged from the chamber 60. The reaction-ready gas mixture 61 enters reactor 70, whereby it remains until the gas mixture is converted to reaction product mixture 71 in a constant volume endothermic reaction. Constant volume reactions are unstable processes that operate in batch mode and require control of flow timing. This is achieved by regulating the flow control in the systems 30, 50 and the separation and control system 80.

The reaction product mixture 71 enters a product separation and control system 80 which stops the reaction in the reactor 70 by reducing the pressure and temperature of the desired reaction product mixture 71 and separates and/or purifies individual product components 81, 82, undesired products 83 and recycle gas mixture 84. The recycle gas mixture 84 enters a preconditioned recycle gas system 90, wherein the recycle gas mixture 84 is preconditioned to a desired temperature and pressure, and flows to the feed mixture conditioning and control system 50.

In some embodiments, the combustible gas 10 and the feed gas 40 are natural gas, and the oxidant gas 20 is air. The desired reaction in reactor 70 is methane pyrolysis, generally given by the following equation:

CH₄(methane) + energy → C (carbon) +2H₂(Hydrogen)

The individual product 81 is hydrogen, the individual product 82 is carbon, and the unwanted products 83 are primarily carbon dioxide, nitrogen and water. The recycle gas mixture 84 comprises primarily unreacted natural gas, hydrogen, nitrogen, and carbon monoxide.

The system in fig. 9 is similar to the system in fig. 8, except that the chamber 60 and the reactor 70 are integrated into the constant volume reactor 62.

FIG. 10 is similar to FIG. 9, but a portion of the recirculation mixture 84 is conditioned in a preconditioned recirculation gas conditioner 90, sent to the combustible gas conditioner and control system 30 to offset the amount of combustible gas 10 required.

Fig. 11 shows a cross-sectional view of a chamber 60 or constant volume reactor 62. In this specification, it refers to a constant volume reactor 62.

The constant volume reactor 62 includes a combustion volume 65 contained within a combustion chamber 63. The combustion chamber 63 is surrounded by a reactor volume 64 contained in a reaction chamber 68. A passage 66 connects the combustion volume 65 to the reactor volume 64. Although the combustion chamber 63 is shown as being centrally located in the reaction chamber 68, the combustion chamber 63 may be located anywhere in the reaction chamber 68, including against the outer wall 69 of the reaction chamber 68.

The conditioned combustible gas mixture 31 enters the combustion chamber 63 through the combustible gas mixture valve 32 and the passage 33, and any combustion product gas mixture 67 present in the combustion volume 65 is removed from the reactor 62 via the passage 74 and the combustion product valve 75. The conditioned feed gas mixture 51 enters the mixing chamber 68 through the feed gas mixture valve 52 and passage 53, and the desired reaction product mixture 71 in the reactor volume 64 is removed from the reactor 62 via passage 73 and product valve 72. Both the conditioned combustible gas mixture 31 and the conditioned feed gas mixture 51 can enter the constant volume reactor 62 at the same time and at the same pressure so that there is very little mixing via the passage 66.

Once essentially all of combustible gas mixture 67 and desired product mixture 71 are removed from reactor 62, combustion product valve 75 and product valve 72 are closed. Once the desired reactor pressure is reached, the combustible gas mixture valve 32 and the feed gas mixture valve 52 are closed, creating an enclosed volume in the reactor 62. The igniter 100 generates ignition energy 101 that allows the conditioned combustible gas mixture 31 in the combustion chamber 63 to combust at an elevated temperature and pressure in an exothermic reaction that produces the combustion product gas mixture 67. Due to the pressure difference created between the combustion chamber 63 and the mixing chamber 68, a portion of the combustible gas mixture 67 enters the reactor volume 64, compressing the raw gas mixture 51 to a higher pressure. At the same time, portions of the hot combustible gas mixture 67 mix and heat the feed gas mixture 51 by conduction, convection, and radiation. The feed gas mixture 51 is now at an elevated temperature and pressure, which creates conditions for an endothermic reaction to occur. The constant volume reactor 62 is maintained in a closed volume until the endothermic reaction is conducted for a sufficient time to produce the desired product mixture 71. Once conditions are reached, the product valve 72 and combustion product valve 75 are opened, which reduces the pressure and temperature, stopping the endothermic reaction. The process is then repeated.

Fig. 12 shows an embodiment of a chamber 60 or constant volume reactor 62 with a combustion chamber 63 outside of a mixing chamber 68. The combustion volume 65 is connected to the reactor volume 64 via a plurality of channels 68. If desired, multiple igniters may be positioned along the combustion chamber 63 to create specific combustion conditions. Multiple igniters may also be positioned in the constant volume reactor 62 of fig. 11 if the combustion chamber 63 is positioned proximate to the reaction chamber wall 69.

Fig. 13 shows an isometric view of an embodiment of the chamber 60 or constant volume reactor 62 in which the combustion chamber 63 is directly joined with a reaction chamber wall 69 of a reaction chamber 68. Directly bonding combustion chamber 63 to reactor chamber wall 69 provides structural support and alignment for combustion chamber 63 and essentially creates a single piece chamber 60 or a constant volume reactor 62.

To create a quasi or semi-continuous flow system, multiple chambers 60 or constant volume reactors 62 may be arranged together and operated asynchronously such that each chamber or reactor undergoes different portions of the process described in fig. 11.

Fig. 14 illustrates an embodiment of a multi-tube reactor 110 in which a plurality of individual constant volume reactors 62 shown in fig. 14 are arranged in a circular pattern. The conditioned combustible gas mixture 31 enters the multi-tube reactor 110 via passage 34 into plenum 35. The conditioned feed gas mixture 51 enters the multi-tube reactor 110 via passage 54 into plenum 55. The timing of the conditioned combustion and conditioned feed gas mixture entering the multitubular reactor 110 is controlled by an inlet rotary valve 120 which is part of a rotary valve assembly 121. The inlet rotary valve 120 performs the same function as the combustible gas mixture valve 32, the passage 33, the raw gas mixture valve 52 and the passage 53 described in fig. 11. The timing of the combustion product gas mixture 67 and the desired product mixture 71 exiting the multi-tube reactor 110 is controlled by an outlet rotary valve 122 which is part of a rotary valve assembly 121. Outlet rotary valve 122 performs the same functions as combustion product valve 72, passage 73, feed product valve 75, and passage 74 described in FIG. 11.

The combustion product gas mixture 67 from each constant volume reactor 62 is collected in the combustion product plenum 123 and distributed out of the multi-tube reactor 110 via channels 125. The product mixture 71 from each constant volume reactor 62 is collected in a product plenum 124 and distributed out of the multitube reactor 110 by a passage 126.

Although the present invention is presented primarily in the context of feedstock gas cracking, the present invention extends to other methods of producing one or more products from a feedstock gas. For example, synthesis gas (H)₂And CO) may be produced by adjusting one or more parameters of the process such that the combustible gas reacts with (in addition to mixing with) the feed gas. For example, the ratio of oxidant to recycle gas in the combustible gas may be increased to increase the pressure and temperature of the combustible gas immediately after ignition to cause an appropriate reaction between the combustible gas and the feed gas.

Although the present disclosure has been described in conjunction with specific embodiments, it is to be understood that the present disclosure is not limited to those embodiments, and that changes, modifications, and variations may be made by those skilled in the art without departing from the scope of the present disclosure. It is further contemplated that any portion of any aspect or embodiment discussed in this specification can be implemented or combined with any portion of any other aspect or embodiment discussed in this specification.

Claims

1. A method of producing one or more products, comprising:

introducing a feed gas into a mixing chamber, wherein the feed gas comprises one or more gases;

introducing a combustible gas into a combustion chamber, wherein the combustible gas comprises one or more gases; and

thereafter, the combustible gas is ignited to flow into the mixing chamber via one or more fluid flow paths between the combustion chamber and the mixing chamber and mix with the feed gas, wherein energy is transferred from the combustible gas to the feed gas to produce one or more products.

2. The method of claim 1, wherein the feed gas and the combustible gas are introduced in a manner such that the feed gas is substantially not mixed with the combustible gas prior to ignition.

3. The method of claim 1 or 2, further comprising stopping further production of the one or more products.

4. The method of any one of claims 1 to 3, further comprising preheating the feedstock gas prior to introducing the feedstock gas into the mixing chamber.

5. The method of any one of claims 1 to 4, further comprising preheating the combustible gas prior to introducing the combustible gas into the combustion chamber.

6. The method of any of claims 1-5, wherein a ratio of a volume of the mixing chamber to a volume of the combustion chamber is less than or approximately equal to 10: 1.

7. The method of any of claims 1-6, wherein a ratio of a length of the mixing chamber to a diameter of the mixing chamber is less than or about equal to 30: 1.

8. The method of any one of claims 1 to 7, wherein the feed gas comprises natural gas.

9. The method of claim 8, wherein the feed gas comprises a mixture of natural gas and recycle gas.

10. The method of claim 9, wherein the recycle gas comprises one or more of: natural gas; hydrogen gas; carbon monoxide; and carbon dioxide.

11. The method of any one of claims 1 to 10, wherein the combustible gas comprises an oxidant.

12. The method of claim 11, wherein the oxidant comprises one or more of oxygen and air.

13. The method of claim 11 or 12, wherein the combustible gas comprises CH₄And O₂A mixture of (a).

14. The method of any one of claims 11 to 13, wherein the combustible gas comprises a mixture of recycle gas and an oxidant.

15. The method of claim 14, wherein the recycle gas comprises one or more of: natural gas; hydrogen gas; carbon monoxide; and carbon dioxide.

16. The method of any one of claims 1 to 15, wherein the combustible gas is introduced into the combustion chamber simultaneously with the introduction of the feed gas into the mixing chamber.

17. The method of any one of claims 1 to 16, wherein the combustible gas is introduced into the combustion chamber at a pressure equal to the pressure at which the feed gas is introduced into the mixing chamber.

18. The method of any one of claims 1 to 17, wherein the one or more products comprise one or more of hydrogen and carbon.

19. The method of any one of claims 1 to 17, wherein the one or more products comprise one or more of hydrogen and carbon monoxide.

20. The method of any one of claims 1 to 17, wherein the one or more products comprise one or more of hydrogen, nitrogen, and carbon.

21. The method of claim 3, wherein stopping further production of the one or more products comprises reducing pressure within the mixing chamber.

22. The method of claim 21, wherein the pressure within the mixing chamber is reduced sufficiently rapidly to inhibit carbon deposition of the mixing chamber.

23. The method of claim 22, wherein the pressure within the mixing chamber decreases by at least 50% in less than 1 second.

24. The method of any one of claims 1 to 23, wherein the pressure wave generated by the combustion of the combustible gas inhibits carbon deposition of the mixing chamber.

25. The method of any one of claims 1 to 24, wherein the energy is transferred from the combustible gas to the feed gas via gas dynamic compression and mixing.

26. The method of any one of claims 1 to 25, wherein at least a portion of the mixture of the feed gas and the combustible gas is transferred to a third chamber after the combustible gas is mixed with the feed gas and before the one or more products are produced.

27. A feed gas reactor comprising:

a mixing chamber;

a combustion chamber;

a valve for controlling gas flow into and out of the mixing chamber and the combustion chamber;

an igniter; and

one or more controllers configured to perform a method comprising:

controlling the valve to introduce a feed gas into the mixing chamber, wherein the feed gas comprises one or more gases;

controlling the valve to introduce a combustible gas into the combustion chamber, wherein the combustible gas comprises one or more gases; and

thereafter, the igniter is controlled to ignite the combustible gas to cause the combustible gas to flow into the mixing chamber via one or more fluid flow paths between the combustion chamber and the mixing chamber and to mix with the feed gas, wherein energy is transferred from the combustible gas to the feed gas to produce one or more products.

28. The reactor of claim 27, wherein the feed gas and the combustible gas are introduced such that the feed gas is substantially unmixed with the combustible gas.

29. The reactor of claim 27 or 28, wherein the method further comprises controlling the valve to stop further production of the one or more products.

30. The reactor of any one of claims 27 to 29, wherein the combustion chamber is located within the mixing chamber.

31. The reactor of claim 30, wherein the combustion chamber is offset relative to a longitudinal axis of the mixing chamber.

32. The reactor of any one of claims 27 to 29, wherein the combustion chamber is located outside the mixing chamber.

33. The reactor of any one of claims 27 to 32, wherein the combustion chamber comprises one or more holes formed therein.

34. A feed gas reactor comprising:

a mixing chamber;

a combustion chamber comprising one or more apertures formed therein, wherein the one or more apertures provide one or more fluid flow paths from the combustion chamber to the mixing chamber;

a valve for controlling gas flow into and out of the mixing chamber and the combustion chamber; and

an igniter.

35. A system, comprising:

a plurality of feed reactors, each reactor comprising:

a mixing chamber;

a combustion chamber; and

an igniter;

one or more controllers configured to perform a method comprising, for each reactor:

controlling the valve to introduce a combustible gas into the combustion chamber, wherein the feed gas comprises one or more gases; and is

Thereafter, controlling the igniter to ignite the combustible gas to cause the combustible gas to flow into the mixing chamber via one or more fluid flow paths between the combustion chamber and the mixing chamber and to mix with the feed gas, wherein energy is transferred from the combustible gas to the feed gas to produce one or more products,

wherein for a given reactor, the process is performed asynchronously with respect to at least one other reactor of the plurality of reactors.

36. The system of claim 35, wherein, for each reactor, the feed gas and the combustible gas are introduced such that the feed gas is substantially not mixed with the combustible gas.

37. The system of claim 35 or 36, wherein for each reactor, the method further comprises controlling the valve to stop further production of one or more products.

38. The system of any one of claims 35 to 37, wherein the plurality of reactors are arranged radially about a central axis, and wherein the system further comprises a rotator configured to: rotating the plurality of reactors about the central axis relative to a valve assembly comprising the valve; or rotating a valve assembly comprising the valve about the central axis relative to the plurality of reactors.

39. A system, comprising:

one or more reactors according to any one of claims 27 to 34; and

one or more fuel cells connected to the one or more reactors and configured to receive carbon produced by mixing the combustible gas with the feedstock gas.