EP-4735162-A1 - A CATALYST ASSEMBLY AND METHOD OF ASSEMBLING SAME

EP4735162A1EP 4735162 A1EP4735162 A1EP 4735162A1EP-4735162-A1

Abstract

A catalyst assembly comprising two or more adjacent structured catalysts for catalysing an endothermic reaction of a feed gas being converted to a product gas, each structured catalyst comprising a macroscopic structure, the macroscopic structure comprising an electrically conductive material for resistance heating and supporting a catalytically active material, wherein: the structured catalysts each extend longitudinally from a first end forming an inlet for feed gas to a second end forming an outlet for product gas; and the assembly comprises a support structure that is electrically insulated from the electrically conductive material and provides a gaseous seal between the structured catalysts, to substantially prevent feed gas flow therebetween.

Inventors

THOMSEN, SØREN GYDE
HANSEN, ANDERS HELBO
BOE, MICHAEL
THOMSEN, Uffe Bach
MORTENSEN, PETER MØLGAARD

Assignees

Topsoe A/S

Dates

Publication Date: 20260506
Application Date: 20240628

Claims (14)

1 . A catalyst assembly comprising two or more adjacent structured catalysts for catalysing an endothermic reaction of a feed gas being converted to a product gas, each structured catalyst comprising a macroscopic structure, the macroscopic structure comprising an electrically conductive material for resistance heating and supporting a catalytically active material, wherein: the structured catalysts each extend longitudinally from a first end forming an inlet for feed gas to a second end forming an outlet for product gas; and the assembly comprises a support structure that is electrically insulated from the electrically conductive material and provides a gaseous seal between the structured catalysts, to substantially prevent feed gas flow therebetween, and wherein the support structure is selected from the group consisting of • a support structure comprising a container or enclosure containing a castable material between and/or surrounding the structured catalysts, and • a support structure comprising a support member having one or more openings for receiving the structured catalysts, and a flexible sealing member disposed around and/or circumscribing the openings.
2. The assembly of claim 1 , wherein the support structure encapsulates the structured catalysts, preferably around their respective inlets.
3. The assembly of claim 1 or 2, wherein: the container or enclosure comprises a metallic or ceramic outer wall containing the castable material; and/or the container or enclosure comprises a metallic or ceramic inner wall around each structured catalyst; and/or the castable material comprises a flowable material comprising a ceramic and is configured to subsequently harden.
4. The assembly of claim 1 or 2, wherein: the sealing member is compressible; and/or the sealing member comprises a ceramic- and/or silicone- based sealing member; and/or the sealing member comprises one or more of: a gasket, an o-ring, putty, rope and/or gland packing.
5. The assembly of claim 1 , 2 or 4, wherein: the support member comprises recesses circumscribing the openings for the structured catalysts, the recesses being configured to receive the sealing member; and/or the support structure comprises a fastener configured to compress the sealing member; and/or the support structure comprises bellows configured to permit thermal expansion of the structured catalysts in one or more axes.
6. The assembly of any preceding claim, wherein the support structure: is shaped to direct feed gas flow to the inlets; and/or is configured to at least partially fill at least some of any space(s) between the adjacent structured catalysts; and/or provides the gaseous seal substantially at or proximal to the first ends of the structured catalysts; and/or has an electrical resistance of > 1000 Ohm, > 10 kOhm, > 100 kOhm, or preferably > 1 MOhm; and/or comprises an electrically insulating layer, electrically insulating the support structure from the electrically conductive material; and/or is heat resistant, operable in temperatures of up to 600, 800 or 1200 °C, preferably operable at up to 800°C at or proximal to the first end and/or up to 1200°C at or proximal to the second end; and/or has a coefficient of thermal expansion substantially equal to or smaller than a coefficient of thermal expansion of a circumferential wall of the structured catalysts; and/or provides an interference fit, securing the structured catalysts.
7. The assembly of any preceding claim, wherein the macroscopic structures: comprise a circumferential wall encircling an internal space; and/or comprise one or more internal walls forming a plurality of flow channels from the first end to the second end; and/or are substantially circular or rectangular in a cross-section, perpendicular to the longitudinal direction.
8. The assembly of any preceding claim, comprising one or more pairs of first and second structured catalysts wherein the first and second structured catalysts in each pair are electrically connected together substantially at or proximal to their second ends, to provide an electrical current flow path from the first end of the first structured catalyst through the first and the second structured catalysts, to the first end of the second structured catalyst.
9. The assembly of claim 8 comprising at least two pairs of structured catalysts comprising a first pair, a second pair and optionally one or more intermediate pairs, wherein: the first structured catalyst of the first pair is electrically connected substantially at its first end to a conductor, and the second structured catalyst of the first pair is electrically connected substantially at its first end to the first structured catalyst of the second pair or the intermediate pair, the second structured catalyst of the intermediate pair, if present, is electrically connected substantially at its first end to the first structured catalyst of the second pair, and the second structured catalyst of the second pair is electrically connected substantially at its first end to a conductor.
10. The assembly of any preceding claim, further comprising: a filter across one or more of the inlets, for filtering feed gas; and/or a distributor across one or more of the inlets, for distributing feed gas flow across the crosssection of the inlets.
11. A vessel comprising one or more of the assemblies according to any preceding claim, wherein the support structure extends and substantially seals between the structured catalysts and one or more walls of the vessel.
12. A catalytic reactor for catalysing an endothermic reaction of a feed gas, comprising: one or more assemblies or the vessel according to any preceding claim; a shell housing the one or more assemblies, the shell comprising an inlet for receiving feed gas and an outlet for product gas; a thermal insulation layer between the structured catalysts and the shell; and one or more connectors for electrically connecting the one or more assemblies to an external power supply.
13. Use of the catalyst assembly, the vessel or the catalytic reactor of any preceding claim in an endothermic reaction, the reaction optionally comprising one or more of: steam methane reforming, hydrogen cyanide formation, methanol cracking, ammonia cracking, reverse water gas shift and dehydrogenation.
14. A method of assembling a catalyst comprising two or more adjacent structured catalysts for catalysing an endothermic reaction of a feed gas being converted to a product gas, each structured catalyst comprising a macroscopic structure, the macroscopic structure comprising an electrically conductive material for heating by resistance and supporting a catalytically active material, the method comprising: positioning the structured catalysts in a support structure; and providing a gaseous seal between the structured catalysts, to substantially prevent feed gas flow therebetween, optionally, heat treating the assembly in a gaseous atmosphere comprising one or more of nitrogen, oxygen, hydrogen, argon and helium at a temperature of up to 600°C.

Description

A CATALYST ASSEMBLY AND METHOD OF ASSEMBLING SAME Field The disclosure generally relates to a support structure for a catalyst assembly or a catalytic reactor, a method of assembling a catalyst comprising the support structure, and use of the catalyst assembly or catalytic reactor in an endothermic reaction, where heat for the endothermic reaction is provided by resistance heating. Background In electrically heated catalytic reactors for endothermic reactions such as those disclosed in WO2019228797, W02021260108 and WO2023274939 (incorporated herein by reference), gas to be processed is fed to the structured catalysts, which provide heat to the endothermic chemical reaction (e.g. steam methane reforming or reverse water gas shift reactions) by resistance heating. Each structured catalyst comprises a macroscopic structure. The term “macroscopic structure” denotes a structure which is large enough to be visible with the naked eye, without magnification. The dimensions of the macroscopic structure are typically in the range of centimetres or meters. Each structured catalyst may comprise a single macroscopic structure or multiple macroscopic structures. Preferably, the macroscopic structure is extruded, fabricated from corrugated sheet metal or 3D printed, because the pressure drop from the inlet to the outlet may be reduced considerably compared to arrangements where the catalyst material is in the form of pellets or similar. The macroscopic structure comprises an electrically conductive material for heating by resistance. The macroscopic structure also supports a catalytically active material, which may be on a ceramic coating such as in WO2023274939A1 , and may be provided on at least part of the exposed surface area of the macroscopic structure. The surface area of the macroscopic structure itself, the fraction of the macroscopic structure coated with a ceramic coating, the type, features and structure (e.g. particle size, typically within the range of 2 nm - 1000 nm, thickness typically in the range of 10-500 pm) of the coating and the amount and composition of the catalytically active material may be suitably tailored to the reaction and operating conditions. Synthesis gas production typically takes place in large chemical plants, due to the energy intensive reactions needed to facilitate the production. The toxicity of the synthesis gas (especially due to the content of carbon monoxide) poses a significant risk. There is a need to improve the efficiency of such reactions, to minimise power consumption and losses of potentially toxic gases. Brief summary of the invention The present invention provides a catalyst assembly comprising two or more adjacent structured catalysts for catalysing an endothermic reaction of a feed gas being converted to a product gas, each structured catalyst comprising a macroscopic structure, the macroscopic structure comprising an electrically conductive material for resistance heating and supporting a catalytically active material, wherein: the structured catalysts each extend longitudinally from a first end forming an inlet for feed gas to a second end forming an outlet for product gas; and the assembly comprises a support structure that is electrically insulated from the electrically conductive material and provides a gaseous seal between the structured catalysts, to substantially prevent feed gas flow therebetween, and wherein the support structure is selected from the group consisting of • a support structure comprising a container or enclosure containing a castable material between and/or surrounding the structured catalysts, and • a support structure comprising a support member having one or more openings for receiving the structured catalysts, and a flexible sealing member disposed around and/or circumscribing the openings. The present invention further provides a method of assembling a catalyst comprising two or more adjacent structured catalysts for catalysing an endothermic reaction of a feed gas being converted to a product gas, each structured catalyst comprising a macroscopic structure, the macroscopic structure comprising an electrically conductive material for heating by resistance and supporting a catalytically active material, the method comprising: positioning the structured catalysts in a support structure; and providing a gaseous seal between the structured catalysts, to substantially prevent feed gas flow therebetween. The present invention further provides additional embodiments as claimed in the dependent claims. The support structure provides a structural support for a catalyst assembly which may comprise several structured catalysts, which are preferably supported by the support structure substantially at their proximal ends, near their inlets. In some embodiments, two structured catalysts are placed vertically next to each other and are rigidly electrically connected at their distal ends to form a U- shaped pair. Several such U-shaped pairs may be co