EP-4735377-A1 - REACTOR MODULE

Abstract

The invention relates to an ammonia cracker reactor module comprising a heat exchanger, and a catalyst cartridge. The reactor module comprises a process fluid module inlet, a process fluid module outlet, a working fluid module inlet and a working fluid module outlet. The heat exchanger and catalyst cartridge are arranged such that a process fluid entering the reactor module through the process fluid module inlet passes through the catalyst cartridge and heat exchanger before passing to the process fluid module outlet. The catalyst cartridge comprises a catalyst material arranged to contact a process fluid passing therethrough to catalyse a reaction to convert ammonia in the process fluid into hydrogen. The heat exchanger is arranged such that a working fluid entering the reactor module through the working fluid module inlet passes through the heat exchanger before passing to the working fluid module outlet, the heat exchanger being arranged to transfer heat between a process fluid and a working fluid flowing therethrough. The catalyst cartridge is removably associated with a process fluid heat exchanger inlet and / or a process fluid heat exchanger outlet such that the catalyst cartridge can be separated from the heat exchanger. The invention extends to a catalyst cartridge for such a reactor module and to a fuel system using such a module.

Inventors

• GRAY, PETER

Assignees

• Catalsys Limited

Dates

Publication Date

20260506

Application Date

20240626

Claims (20)

1. 1. An ammonia cracker reactor module comprising a heat exchanger, and a catalyst cartridge, wherein: the reactor module comprises a process fluid module inlet, a process fluid module outlet, a working fluid module inlet and a working fluid module outlet; the heat exchanger and catalyst cartridge are arranged such that a process fluid entering the reactor module through the process fluid module inlet passes through the catalyst cartridge and heat exchanger before passing to the process fluid module outlet; the catalyst cartridge comprises a catalyst material arranged to contact a process fluid passing therethrough to catalyse a reaction to convert ammonia in the process fluid into hydrogen; the heat exchanger is arranged such that a working fluid entering the reactor module through the working fluid module inlet passes through the heat exchanger before passing to the working fluid module outlet, the heat exchanger being arranged to transfer heat between a process fluid and a working fluid flowing therethrough; the catalyst cartridge is removably associated with a process fluid heat exchanger inlet and I or a process fluid heat exchanger outlet such that the catalyst cartridge can be separated from the heat exchanger.
2. 2. A reactor module as claimed claim 1, in which the reactor module comprises a second catalyst cartridge and in which the catalyst cartridge is associated with a process fluid heat exchanger inlet and the second catalyst cartridge is associated with a process fluid heat exchanger outlet.
3. 3. A reactor module as claimed in claim 1 or claim 2, in which the reactor module comprises at least one electrically heated catalyst arranged such that process fluid passing from the process fluid inlet to the process fluid module outlet passes through the electrically heated catalyst, the electrically heated catalyst comprises a catalyst material arranged to contact a process fluid passing therethrough to catalyse a reaction to convert ammonia in the process fluid into hydrogen.
4. 4. A reactor module as claimed in claim 3, in which the at least one electrically heated catalyst comprises two electrically heated catalysts arranged in series.
5. 5. A reactor module as claimed in any previous claim, in which the reactor module comprises a housing within which the heat exchanger and catalyst cartridge are located.
6. 6. A reactor module as claimed in any claim 5, in which the housing is thermally insulated.
7. 7. A reactor module as claimed in any preceding claim, in which the heat exchanger comprises a welded plate heat exchanger having a plate side and a shell side.
8. 8. A reactor module as claimed in claim 7, in which the heat exchanger is arranged such that the process fluid passes through the plate side of the heat exchanger and the heat exchanger comprises an internal plate side inlet manifold and an internal plate side outlet manifold.
9. 9. A reactor module as claimed in claim 7, in which the internal plate side inlet manifold and internal plate side outlet manifold each comprise a substantially cylindrical void.
10. 10. A reactor module as claimed in claim 8 or claim 9, in which the catalyst cartridge is associated with a process fluid heat exchanger inlet and I or a process fluid heat exchanger outlet by being removably arranged within the internal plate side inlet manifold or the internal plate side outlet manifold.
11. 11. A reactor module as claimed in claim 10, in which the heat exchanger comprises a welded plate heat exchanger having a plate side and a shell side and arranged such that the process fluid passes through the plate side of the heat exchanger and the heat exchanger comprises an internal plate side inlet manifold and an internal plate side outlet manifold, and in which the catalyst cartridge is associated with a process fluid heat exchanger inlet by being removably arranged within the internal plate side inlet manifold and the second catalyst cartridge is associated with a process fluid heat exchanger outlet by being removably arranged within the internal plate side outlet manifold.
12. 12. A reactor module as claimed in claim 11 , in which the reactor module includes at least one access port closed by a cover, removal of the cover allowing access to one of the internal plate side inlet manifold and the internal plate side outlet manifold such that a catalyst cartridge located therein can be removed through the access port.
13. 13. A reactor module as claimed in claim 12, in which the process fluid inlet port and the access port are located adjacent one another in a first end of the reactor module.
14. 14. A reactor module as claimed in any preceding claim, in which the catalyst cartridge can be moved relative to the heat exchanger during operation of the reactor module.
15. 15. A catalyst cartridge for a reactor module, the catalyst cartridge comprising a catalyst material arranged to contact a process fluid passing therethrough to catalyse a reaction to convert ammonia in the process fluid into hydrogen, the catalyst cartridge extending along a first axis and having an axial opening and a transverse opening such that a process fluid can flow into or out of the catalyst cartridge along the first axis and can flow out of or into the catalyst cartridge transverse to the first axis.
16. 16. A catalyst cartridge as claimed in claim 15, in which the catalyst cartridge extends along a catalyst axis and comprises an axial flow support which carries the catalyst material, the axial flow support defining a plurality of flow channels which extend substantially parallel with the catalyst axis
17. 17. A catalyst cartridge as claimed in claim 16, the axial flow support defining a plurality of radial flow gaps.
18. 18. A catalyst cartridge as claimed in claim 17, in which the radial flow gaps are defined by a plurality of radial slots formed in the axial flow support.
19. 19. A catalyst cartridge as claimed in claim 17 or claim 18, in which the radial flow gaps are defined by a plurality of radial slots formed in the axial flow support have dimensions that vary along a length of the catalyst.
20. 20. A catalyst cartridge as claimed in claim 15, in which the catalyst cartridge comprises an open-cell porous support matrix carrying the catalyst material.

Description

Reactor Module The present invention relates to a reactor module for carrying out an ammonia cracking reaction, to a catalyst cartridge for that module, and to a fuel system using such a reactor module. Hydrogen fuel has been proposed as a clean energy solution that, if adopted, could reduce the CO2 emissions associated with the world’s energy production and consumption. Hydrogen is considered to be a ‘clean’ fuel as it can be created using zero carbon renewable power and consumed and produce water as the sole or major product under the correct conditions. Hydrogen can be stored in gaseous or liquid form and transported as a means of delivering energy to locations and end-users. The transportation of hydrogen presents various challenges. The cost of green hydrogen to the end-user in geographies where it is most in demand such as Europe, North America, and Asia is not economic which impedes the decarbonisation of major CO2 emitting industries such as transport and heating. Green hydrogen produced in the regions of demand is often made via the electrolysis of water using renewable electricity. Renewable electricity in these regions is often expensive and so the high cost of energy results in hydrogen with a similarly high associated cost. Much of the world’s energy infrastructure does not currently support hydrogen and remains directed towards the transportation and exploitation of hydrocarbons and fossil fuels. It is possible to convert existing hydrocarbon fuel infrastructure to transport hydrogen fuel into regions where electricity is expensive. However, such conversions have not occurred on a large scale and new technical solutions are needed to allow small-to-medium scale users and applications to utilise hydrogen effectively. The Haber-Bosch process is a well-known equilibrium process that is most commonly used to produce ammonia for applications such as fertiliser through the reaction of hydrogen and nitrogen. The reaction of hydrogen with nitrogen is a reversible reaction, with the forward reaction producing ammonia (the Haber-Bosch process). The manipulation of reaction conditions allows for ammonia to be converted back into hydrogen and nitrogen (known as cracking) and these two reactions occur together to produce an equilibrium. The reliance of world agriculture upon ammonia-based fertilisers has created an ammonia transportation infrastructure that is well-established. Transportation of liquid ammonia has various advantages when compared to the transportation of liquid or gaseous hydrogen. The boiling point of hydrogen is approximately -253°C whereas the boiling point of ammonia is approximately -33°C. The difference in boiling points means that ammonia is significantly less energy intensive to liquify and store in liquid form. Ammonia is less flammable than hydrogen and so is considered safer to transport. The energy density of liquid ammonia is also significantly greater than that of liquid hydrogen. Both ammonia and hydrogen can be used as fuels. The inventors of the present invention have appreciated that the transportation of liquid ammonia, over long distances, as a means of providing a fuel to end-users and applications, is preferable to the transportation of hydrogen in gaseous or liquid form. However, current plans for the conversion of ammonia back to hydrogen are generally intended to be carried out in large-scale centralised facilities which would necessitate the further transport and distribution of the hydrogen produced by the facility to end-users further afield. The present invention provides an ammonia cracker reactor module comprising a heat exchanger, and a catalyst cartridge, wherein: the reactor module comprises a process fluid module inlet, a process fluid module outlet, a working fluid module inlet and a working fluid module outlet; the heat exchanger and catalyst cartridge are arranged such that a process fluid entering the reactor module through the process fluid module inlet passes through the catalyst cartridge and heat exchanger before passing to the process fluid module outlet; the catalyst cartridge comprises a catalyst material arranged to contact a process fluid passing therethrough to catalyse a reaction to convert ammonia in the process fluid into hydrogen; the heat exchanger is arranged such that a working fluid entering the reactor module through the working fluid module inlet passes through the heat exchanger before passing to the working fluid module outlet, the heat exchanger being arranged to transfer heat between a process fluid and a working fluid flowing therethrough; the catalyst cartridge is removably associated with a process fluid heat exchanger inlet and I or a process fluid heat exchanger outlet such that the catalyst cartridge can be separated from the heat exchanger. Providing a catalyst cartridge that can separated from the heat exchanger of the reactor module provides a significant advantage. The catalyst cartridge can be created and tested se