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Abstract

A fluid-wall reactor for high temperature chemical reactions is described, the reactor comprising (A) a porous reactor tube, at least a portion of the interior of which defines a reaction zone, the tube being made of a fabric of a fibrous refractory material; (B) a pressure vessel enclosing the reactor tube to define an inert fluid plenum, the pressure vessel having at least one inlet for admitting the inert fluid which is directed under pressure through the porous tube wall to provide a protective blanket for the inside surface of the reactor tube; (C) means for introducing at least one reactant into the reaction zone, the reactants being directed in a predetermined path axially of the reactor tube and being confined by the protective blanket substantially centrally within the reaction zone; (D) means disposed within the plenum for heating the reactor tube to the temperature level at which it emits sufficient radiant energy to initiate and sustain the desired chemical reaction, the radiant energy being directed into the reaction zone to coincide with at least a portion of the path of the reactants; and (E) a heat shield disposed within the pressure vessel, substantially enclosing the heating means and the reaction zone to define a black body cavity, the heat shield reflecting radiant energy toward the reaction zone. The fluid-wall reactor of the invention may be used in virtually any high temperature chemical reaction, many of which reactions have been previously regarded as impractical or only theoretically possible. Among the reactions which may be carried out in the fluid-wall reactor of the invention as the dissociation of hydrocarbons and hydrocarbonaceous materials, such as coal and various petroleum fractions, into hydrogen and carbon black; the steam reforming of coal, petroleum fractions, oil shale, tar sands, lignite, and any carbonaceous or hydrocarbonaceous feedstock into synthesis gas mixtures; the partial dissociation of hydrocarbons and hydrocarbonaceous materials into lower molecular weight compounds; the partial pyrolysis of saturated hydrocarbons into unsaturated hydrocarbons, such as ethylene, propylene and acetylene; the conversion of organic waste materials, such as sewage sludge, into a fuel gas; the complete or partial desulfurization of sulfur-containing hydrocarbonaceous feedstocks; and the reduction of mineral ores with hydrogen, carbon, synthesis gas, or other reducing agent.

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First Claim