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    • 专利摘要:
    A solar reforming reactor for reforming a reactant mixture comprising a hydrocarbon fuel at a target reforming temperature to produce synthesis gas. The reforming reactor comprises a plurality of elongate tubular reactor sections arranged about a common central axis, each tubular reactor section being arranged to extend about and/or around the common central axis. Figure 5 C:pof~wordSPCN-972351 .docx -1 4 FI 2' 3, 0
    公开号:AU2013206238A1
    申请号:U2013206238
    申请日:2013-06-07
    公开日:2014-01-16
    发明作者:Regano Benito；Glenn Hart；Stephen Mcevoy；Robbie Mcnaughton
    申请人:Commonwealth Scientific and Industrial Research Organization CSIRO；
    IPC主号:B01J8-06
    专利说明:
    1 SOLAR REFORMING REACTOR CROSS-REFERENCE [0001] This application claims priority from Australian Provisional Patent Application No. 2012902596 filed on 20 June 2012, the contents of which are to be taken as incorporated herein by this reference. FIELD OF THE INVENTION [0002] The present invention generally relates to a solar reforming reactor for reforming a reactant mixture to produce synthesis gas. More particularly, the invention relates to a solar reforming reactor which includes a plurality of elongate tubular reactors for producing synthesis gas using concentrated solar energy. BACKGROUND OF THE INVENTION [0003] The following discussion of the background to the invention is intended to facilitate an understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application. [0004] Steam reforming of methane to produce syngas is an established industrial process in which methane and steam are reformed to synthesis gas at a temperature of greater than 7501C, and more typically at a temperature of around 9001C. These conditions enable the followin g adiabatic chemical reaction: CH4(g) + H2O(g) <- 3H2(g) + CO(g) AH 2 9 8 K = 206 kJ mol- 1 (1) [0005] A dry reforming reaction for producing syngas is also possible according to the following reaction: CH4(g) + CO2(g) = H2(g) + 2CO(g) AH298K = 247 kJ mol- 1 (2) Tubular solar reformer - first drait prove 2 [0006] The highly endothermic reforming chemical reactions (1) and (2) are performed at a reforming temperature in the presence of a suitable reforming catalyst. [0007] Steam reforming and/or dry reforming is traditionally is carried out in reactors containing catalyst-filled tubes which are heated to that temperature by the combustion of one or more gaseous hydrocarbons, typically off-gas from the reforming process. This process has high C02 emissions. [0008] Solar steam reforming provides an alternate process in which the reforming temperature is achieved through concentrated solar radiation. To provide the necessary heat input, the carbon-hydrogen-containing species and the water are heated to the reforming temperature using solar energy. The solar energy is in a concentrated form derived from heliostat fields or the like. The concentrated solar energy is typically focused upon a solar receiver, which also functions as a reforming reactor. Advantageously, any off-gas produced from the reforming reaction can be recycled within the process keeping the unavoidable C02 emissions as low as possible. [0009] A number of solar reforming configurations have been previously proposed. Examples include conical vessel type reactor configurations which included a conical solar concentrator which concentrate solar energy onto a conical receiver which is inset into a catalytic chamber through which the reactants flow. Other configurations include a honeycomb reactor configuration, comprising a multitude of close packed catalyst filled cavities, and catalyst packed tubular reactors comprising coiled or stacked elongate lengths of unitary tubes. [0010] All of the proposed reactors require a high degree of engineering to withstand the temperatures and pressure required to be maintained within the large and/or elongate spaces provided in the reactors. For example, conical reactor configurations require complex design and arrangement of the individual components within the reactor, requiring a number of joints that can have sealing problems. Coiled elongate catalyst packed tubular reactors are typically Tubular solar reformer - first drait prove 3 formed from a number of welded lengths of tubes. Each weld provides a potential failure or leak point in the reactor, particularly at the selected reforming temperature and conditions. Furthermore, the long tubular length provides a significant pressure drop along the length of the reactor. In some solar reformer designs (e.g. parallel tubes with common inlet and outlet manifolds), the thermal expansion of the tubes relative to each other and relative to the manifolds result in severe stresses around the joints requiring more expensive tube materials. [0011] It would therefore be desirable to provide an improved and/or alternative solar reforming reactor. SUMMARY OF THE INVENTION [0012] The present invention provides in a first aspect a solar reforming reactor for reforming a reactant mixture comprising a hydrocarbon fuel at a target reforming temperature to produce synthesis gas. The reforming reactor comprises a plurality of elongate tubular reactor sections arranged about a common central axis, each tubular reactor section being arranged to extend about and/or around the common central axis. The reactor preferably comprises an inner tube housed within an outer tube. More preferably, a reforming catalyst is located in the inner tube or between the outer and inner tube (e.g. the annular space between the inner and outer tube). [0013] The solar reforming reactor of the present invention includes a plurality of elongate tubular reactor sections with a target area, preferably the focal area of a heliostat field, in which the reforming reaction takes place. The use of a plurality of tubular reactors allows shorter tubular reactors to be used when compared to a unitary tubular reactor. Shorter length tubular reactors have a lower pressure drop across the longitudinal length of each reactor. The use of shorter tube lengths also minimises, and in some embodiments with a multitude of tubes, eliminates the need for welded joints and any sealing and/or failure issues associated with such joints. Furthermore, in some embodiments, a plurality of reactor tubes has the advantage over fewer longer tubes as the reaction kinetics favour an initial high rate of hydrogen production. This Tubular solar reformer - first drait prove 4 embodiment is particularly favourable when a water gas shift reactor is coupled downstream to the steam reforming reactor. [0014] In a preferred embodiment, the tubular reactor sections comprise a plurality of different stages, each stage comprising a different tubular reactor wall thickness. Through matching the reaction process conditions with the required material performance, overall wall thickness can be reduced. [0015] For example, the inlet of each tube may have thinner walls relative to the rest of the tube since it will be exposed to lower operating temperatures in spite of high heat fluxes due to the initially high rate of reaction. The diameter of the tubes is preferably progressively reduced from inlet to outlet of each tubular reactor in the direction of increasing wall temperatures. This allows for wall thickness to be matched to the process conditions (i.e. thinner walls in lower temperature/pressure reaction zones). [0016] The use of a plurality of reactor tubes can also facilitate the ease of repair, maintenance and replacement of each of the reactor segments. The multi-component reactor design enables only the components which need to be replaced or repaired to be done so. Thus, maintenance costs are reduced with maintenance able to be achieved when the solar reforming reactor is off-line (i.e. overnight). This design promotes the use of a low capital cost strategy, in which high precision control of the solar flux on the receiver enables less durable (i.e. lower wall thickness) reactor tubes to be used, with more frequent, but targeted replacement and/or repair. [0017] The reforming reactor can comprise any number of multiple tubular reactors. Two tubular reactor sections may be used. However, in order to provide good area coverage within a target solar incident area with short tubular lengths, it is preferred that the reforming reactor comprises at least three elongate tubular reactor sections, and more preferably multiple elongate tubular reactor sections arranged about the common central axis. Tubular solar reformer - first drait prove 5 [0018] Each tubular reactor section is preferably respectively symmetrically arranged about the common central axis. This allows for a substantially even distribution of incident solar energy on each tubular reactor section when the solar reforming reactor is in use. [0019] Each tubular reactor section is also preferably respectively substantially radially aligned within a plane. Planar alignment allows to easy mounting within a housing and minimizes shadows created by the overlap or interference of a portion of one tubular reactor section on another tubular reactor section of the solar reforming reactor. Nevertheless, in some embodiments the tubes of each respective tubular reactor section may be arranged in an intertwined or overlapping arrangement about the common central axis. The intertwined or overlapping arrangement enables a more compact arrangement to be configured about the common central axis [0020] The inlet and/or outlets of each tubular reactor section may also be geometrically arranged around and about the common central axis. In some embodiments, the reactant feed inlet of each tubular reactor section is evenly annularly spaced apart about the common central axis. In some embodiments, each tubular reactor section includes a first reactant inlet which extends, preferably axially extends relative to the common central axis, into the geometric center of the layout of the outer and inner tubes. In some embodiments, each tubular reactor section includes a second reactant inlet that extends radially inwards towards the common central axis of the layout of the outer and inner tubes relative to the common. [0021] The tubular reactor sections may be any suitable configuration or shape. The preferred geometric configuration is to maximise capture of incident solar energy and to position the hydrocarbon inlet at maximum solar flux. [0022] In some embodiments, each tubular reactor section includes at least one arcuate section. Each tubular reactor section is preferably configured to include at least one arcuate section which curves at least 180, more preferably at least Tubular solar reformer - first drait prove 6 2700. Each arcuate section preferably extends abou t and is spaced apart around the common central axis. The arcuate section can in some embodiments comprise a coil having at least one winding extending about and around the common central axis. In some embodiments, the coil or coils of each tubular reactor section can be intertwined as substantially concentrically wound coils. [0023] In other embodiments, each tubular reactor section includes at least one linear section, each linear section being configured to extend radially through or about the common central axis. Preferably, each linear section is annularly spaced apart about the common central axis. [0024] In some embodiments, the cross-sectional size of at least one of the outer tube or each of the outer tube and inner tube increases radially outwardly from the common central axis. Each tubular reactor section can preferably form an arc segment centred on the common central axis. [0025] The tubes of each tubular reactor section can be laid out within a housing which has a central axis extending through the common central axis of the at least two tubular reactor sections. The housing preferably has an axial cross-sectional shape relative to the axis that comprises a circle or polygon, and more preferably a regular polygon, for example a hexagon. [0026] The hydrocarbon fuel fed into the solar reforming reactor may be any fuel comprising a hydrogen-carbon species that is capable of being reformed to produce hydrogen gas, including methane, ethanol and/or methanol. The hydrocarbon fuel is preferably methane or a methane containing gas such as natural gas or biogas. [0027] The reforming reaction in each tubular reactor section preferably includes at least a steam reforming reaction (formula 1) or a dry reforming reaction (formula 2). Depending upon the reforming reaction, the output stream Tubular solar reformer - first drait prove 7 of the reforming reactor will typically comprise varying amounts of carbon monoxide, carbon dioxide, hydrogen, water and methane. [0028] The solar reforming reactor may use any number of suitable tubular reactor configurations for the reforming reactor. One exemplary embodiment comprises a dual tube reactor. In this embodiment, each tubular reactor section preferably includes: an outer tube having a first end and a second end, the second end being axially spaced apart from the first end along the longitudinal length of the outer tube; at least one inner tube, the inner tube being housed within the outer tube and extending within the outer tube from the first end to a mixing location within the outer tube which is longitudinally spaced away from the second end; a catalyst which longitudinally extends within the solar reforming reactor between the mixing location and first end of the outer tube, the catalyst being located either in a first arrangement in which the catalyst is housed within the inner tube; or a second configuration in which the catalyst is housed between the inner tube and outer tube. [0029] In use, the reactants are preferably fed countercurrently into each tubular reactor section. In such a configuration, the reactants preferably comprise: a first reactant comprising at least one hydrocarbon species, the first reactant being fed into each tubular reactor section to flow from the second end of the outer tube to the mixing location; and a second reactant comprising at least one of water, carbon monoxide or carbon dioxide, the second reactant being fed into each tubular reactor section to flow from the first end of the outer tube to the mixing location either between an inner tube and the outer tube when the catalyst is in the first arrangement or through the inner tube when the catalyst is in the second arrangement. [0030] The catalyst preferably axially extends within the solar reforming reactor between the mixing location and a reaction termination location. The reaction termination location can be spaced longitudinally away from the first end of the Tubular solar reformer - first drait prove 8 outer tube of each tubular reactor section. More preferably, the reaction termination location is spaced longitudinally remotely away from the first end of the outer tube to provide a heat transfer zone for heat transfer between components flowing between the outer and inner tube, and components flowing through the inner tube. The heat transfer zone can therefore be used as a heat exchanger to recover the heat in the product gas leaving the reformer reaction zone to preheat the feed water or other reactor. Preferably, the heat transfer zone is used for converting feed water into steam. The heat transfer zone advantageously substantially prevent any water vapour, condensation or other liquid state water from contacting the catalyst and therefore poisoning or otherwise damaging that catalyst. [0031] In some embodiments, each tubular reactor section comprises a plurality of inner tubes. The catalyst is housed between the inner tube and outer tube and in alternating concentric cavities between each concentric inner tube. The second reactant feed therefore flows from the first end of the outer tube to the mixing location in the respective alternate concentric cavities to the catalyst between each concentric inner tube. [0032] The present invention provides in a second aspect an apparatus for the production of synthesis gas comprising: a plurality of heliostats; and a solar energy receiver for receiving solar energy directed thereon from the heliostats and transferring said energy to a reforming reactor according to the first aspect of the present invention. [0033] The apparatus can further comprise a control system that calibrates the thermal flux of the solar energy receiver. The solar energy receiver defines a primary target to receive directed sunlight from a field of heliostats each mounted for angular adjustment to optimally receive a beam of sunlight and direct it to the primary target of the solar energy receiver. The receiver is preferably calibrated through the steps comprising: Tubular solar reformer - first drait prove 9 during operation of the solar energy apparatus, sequentially causing a temporary angular adjustment of the respective said heliostats so as to divert the beam of sunlight received at each heliostat to a secondary target for a predetermined period of time, which secondary target is at or spaced from the primary target and disposed so as not to be intercepted by said optimally received and directed beams of sunlight, thereafter returning the heliostat to a position in which the received beam of sunlight is directed to the primary target, recording a representation of each directed beam at the secondary target; responding to the representation of the diverted beam for the respective heliostats when a parameter or element thereof deviates from a reference norm, by angularly adjusting the corresponding heliostat to improve the accuracy of its receipt of said beam of sunlight and direction of the beam to the primary target, thereby compensating by closed loop control of the field of heliostats during operation of the apparatus for tolerances in heliostat and actuator geometries; and causing a said representation to be acquired for each of multiple heliostats at different times over a day and over an extended period of multiple days and for corresponding angular positions of the heliostat, whereby to obtain a calibration model for the heliostats with respect to multiple time points as well as the geometry of the heliostats, and whereby to achieve a combination of open loop and closed loop control of the positions of the heliostats. [0034] Within this embodiment, said extended period of multiple days preferably comprises a time scale of several months. [0035] Said representation is preferably acquired for each of multiple heliostats at different times over a day at intervals of a plurality of months. [0036] Said obtaining of the calibration model preferably includes use of a weighted and constrained gradient descent method. Tubular solar reformer - first drait prove 10 [0037] Said angular adjustment of the corresponding heliostat preferably comprises an offset selected from a set of offsets determined by calibration measurements taken at multiple time points over a day. [0038] The heat flux of the receiver may be accurately controlled through use of a control system which regularly calibrates the heliostat fields to take into account imprecision in the installation and operation of the heliostat field as well as account for seasonal variations. Accordingly, the temperature of the target reforming reaction temperature may be accurately controlled without the need to use excessively large thermal storage tanks to minimise fluctuations of the target reforming temperature. BRIEF DESCRIPTION OF THE DRAWINGS [0039] The present invention will now be described with reference to the figures of the accompanying drawings, which illustrate particular preferred embodiments of the present invention, wherein: [0040] Figure 1 is a view of a small central receiver solar energy collection system according to an embodiment of the invention; [0041] Figure 2 is a perspective view from below of the tower-mounted central receiver and the secondary target; [0042] Figure 3 is a cross-section of one tubular reactor section from a solar reforming reactor of the present invention. [0043] Figure 4 provides a plan view of the various sections of one tubular reactor section from a solar reforming reactor of the present invention. [0044] Figure 5 shows the configuration of a solar reforming reactor according to one embodiment of the present invention which includes two tubular reactor coils. Tubular solar reformer - first drait prove 11 [0045] Figure 6 shows the configuration of a solar reforming reactor according to one embodiment of the present invention which includes four intertwined tubular reactor coils. [0046] Figure 7 shows the configuration of a solar reforming reactor according to one embodiment of the present invention which includes four sprial tubular reactor coils. [0047] Figure 7A and 7B shows the configuration of a solar reforming reactor according to one embodiment of the present invention which includes four U shaped tubular reactor coils, in which 7A is a plan view of the solar reforming reactor; and 7B is a perspective view of one of the tubular reactor sections. [0048] Figure 8A and 8B shows the configuration of a solar reforming reactor according to one embodiment of the present invention which includes four linear tubular reactor sections in which 8A is a plan view of the solar reforming reactor; and 8B is a perspective view of one of the tubular reactor sections. [0049] Figure 9A and 9B shows the configuration of a solar reforming reactor according to one embodiment of the present invention which includes eight straight tubular reactor sections in which 9A is a plan view of the solar reforming reactor; and 9B is a perspective view of one of the tubular reactor sections. [0050] Figures 10A to 10B shows the configuration of a solar reforming reactor according to one embodiment of the present invention which includes eight segment tubular reactor sections in which 10A is a plan view of the solar reforming reactor; 10B is a perspective view of one of the tubular reactor sections; and 10C is a perspective view of an alternate embodiment of the tubular reactor sections. [0051] Figure 11 is a plan diagram of a suitable field of heliostats for the system depicted in Figure 1. Tubular solar reformer - first drait prove 12 [0052] Figure 12 is a functional block diagram of the main components of the solar energy collection system, including the controller. [0053] Figure 13 is a diagram of the secondary target with a representative flux image of a heliostat-reflected beam. [0054] Figure 14 is a diagrammatic representation of the closed loop control system. DETAILED DESCRIPTION [0055] Figures 1 and 2 illustrate the general arrangement of one form of solar reforming system 10 into which a solar reforming reactor according to the present invention can be incorporated. The system 10 comprises a central solar energy receiver 12 mounted in cantilevered fashion from a tower 11 above and in front of a large array or field 18 of heliostats 15. Heliostats 15 are mounted for angular adjustment to optimally receive a respective beam of sunlight 100 and to direct the beam, as a directed beam 102, to the solar receiver 12. Receiver 12 has an aperture 13 (Figure 2) that defines a primary target to receive the directed beams of sunlight from the heliostats 15. [0056] The solar receiver 12 includes a reactor chamber (not illustrated) which houses a solar reforming reactor of the present invention. The focused energy of the heliostats 15 onto the aperture 13 creates temperatures of over 8001C, typically around 850C, within the reactor chamber for use in a reforming reaction. [0057] Referring now to Figures 3 to 10, it can be seen that a solar reforming reactor 200 of the present invention can have various configurations. However, each configuration has generally the same internal arrangement, as illustrated in Figures 3 and 4. Referring to these figures, the tubular reactor sections 210 of each solar reforming reactor 200 comprises a dual pipe reactor through which a flow stream of a hydrocarbon fuel such as natural gas mixed with steam or carbon dioxide over a catalyst at a target reforming temperature to produce Tubular solar reformer - first drait prove 13 synthesis gas. Each of the solar reforming reactors 206A to 206F shown in Figures 5 to 10 comprises a plurality of elongate tubular reactor sections 202 arranged about a common central axis X-X. Each of the tubular reactor sections 202 have the internal components shown in Figures 3 and 4. [0058] Each of the tubular reactor sections 202 comprises a dual tube reactor having a concentrically arranged outer tube 204 and inner tube 206. The outer tube (or pipe) 204 has a larger diameter than the inner tube (or pipe) enabling the smaller inner tube or pipe 206 to be housed within the outer tube 204. The inner tube 206 extends within the outer tube 206 from a water feed end 208 to a mixing location 210 within the outer tube 204 (Figure 3 and 4). The mixing location 210 is longitudinally spaced away from the hydrocarbon feed end 212 of the outer tube 204. A reforming catalyst 214 is housed in a catalyst bed located between the inner tube 206 and outer tube 204 in a reaction zone 215 within the tubular reactor section 202. The reaction zone 215 is positioned between the mixing location 210 and a reaction termination location 216 (see below) and is positioned within the tubular reactor section 202 in a location which captures a large amount of focused solar energy from the heliostats 15 (Figure 1). [0059] In preferred embodiments, the internal diameter of inner tube 206 decreases as it progresses from the mixing location 210 to the water feed end 208. This decrease in tube diameter may be achieved through the use of progressively smaller internal diameter tube sections. For example, an internal tube diameter of six inches may be used for a six metre length of tube at the mixing location and finish with a six metre tube length of four inch diameter at the water feed end 208 (with the option of further intermediate internal tube diameter lengths in between). The outer tube internal diameter may also decrease in a similar fashion. As the internal diameters of the tubes decrease, the tube thickness increases. Therefore, the most extreme (high temperature/high pressure) environments may be matched with the most resilient materials to thereby extend the reactor's working life. Tubular solar reformer - first drait prove 14 [0060] The catalyst 214 used in the reaction zone 215 can be any one of a number of well know reforming catalysts. One example is the Haldor Topsoe nickel-based stream reforming catalyst R-67-7H. However, it should be appreciated that any suitable reforming catalyst could be used without departing from the spirit and scope of the present invention. [0061] The reforming reaction in each tubular reactor section 202 includes at least a steam reforming reaction (formula 1) or a dry reforming reaction (formula 2) depending on the reactants fed into the solar reforming reactor 200. [0062] In use, the reactants are counter-currently fed into each tubular reactor section 202 from respective inlets at the respective water feed end 208 and hydrocarbon feed end 212. Each elongate tubular reactor section 202 can have its own individual reactant feed control units (not illustrated). [0063] The hydrocarbon fuel fed into hydrocarbon feed end 212 may be any fuel comprising a hydrogen-carbon species that is capable of being reformed to produce hydrogen gas, including methane, ethanol and/or methanol, for example a methane containing gas such as natural gas or biogas. [0064] The second reactant fed into the water feed end 208 through an inlet fluidly connected to the inner tube 206 comprises at least one of water, carbon monoxide or carbon dioxide. [0065] Depending upon the reforming reaction, the output stream of the reforming reactor 200 will typically comprise varying amounts of carbon monoxide, carbon dioxide, hydrogen, water and methane. The synthesis gas produced from the reforming reaction exits through the annular space 222 between the inner tube 206 and outer tube 204 at the product exit 209 which is proximate the water feed inlet 206. [0066] The reaction termination location is spaced longitudinally remotely away from first water feed end 208 and product exit 209. The length of the tubular reactor section between the reaction termination location and product exit 209 Tubular solar reformer - first drait prove 15 form a heating zone 220 for heat transfer between the heated synthesis gas product flowing in that zone between the outer tube 204 and inner tube 206 and feed water flowing in the inner tube 206. As best shown in Figure 4, the heating zone 220 typically extends between the exit of the solar energy receiver 12 at the top of the tower 11 to the water feed inlet 206 at ground level at the bottom of the tower 11. The heating zone 220 can therefore be used as a heat exchanger to recover the heat in the product gas leaving the reformer reaction zone to preheat the feed water and/or converting that feed water into steam prior to contact with the catalyst 215. [0067] The amount of heat transfer in the heating zone 220 can be controlled to produce a desired synthesis gas product temperature. For example, where further downstream reactions are to be carried out (for example low temperature water gas-shift to produce more hydrogen), heat recovery in the heating zone 220 could be limited to cooling the reformer product gas to appropriate temperatures (for example 200C as required in the low temperature water gas shift reaction). [0068] Each tubular reaction section 202 is operated at a temperature of around 850C and a pressure of around 1MPa. The tubular reactor sections are preferably constructed from high temperature metal alloys, such as high temperature stainless steel. Depending on capacities of the solar reformer reactor, schedule 80 (and above) pipes with nominal sizes from 4 to 6 inches can be used. [0069] The tubular reactor sections 202 can have a large variety of geometric configurations, examples of which are illustrated in Figures 5 to 10. The preferred geometric configuration is to maximise capture of incident solar energy and to position the inlet at maximum solar flux. The reformer is therefore preferably configured to minimise gaps between adjacent tubes of the respective tubular reactor sections 202. The preferred geometry is dependent on each specific reforming application. In some embodiments, a water gas shift reactor (not illustrated) may be coupled or otherwise fluidly connected Tubular solar reformer - first drait prove 16 downstream to the steam reforming reactor. In this embodiment, a plurality of shorter tubular reactor sections 202 has the advantage over fewer longer tubes as the reaction kinetics favour an initial high rate of hydrogen production. [0070] Each of the tubular reactors 200A to 200F shown in Figures 5, 6, 7, 7A to 10 are laid out within a hexagonal housing 250 having a central axis X-X. The tubular reactor 200X shown in Figure 7 is laid out within a circular housing 250X having a central axis X-X. It is to be understood that a variety of other housing shapes could also be used, such as square, pentagonal, octagonal or another regular polygon, and the present invention should therefore not be limited to any particular housing configuration. Each of the tubular reactor sections 202 substantially symmetrically extend about and/or around that common central axis X-X of the at least two tubular reactor sections. This allows for a substantially even distribution of incident solar energy on each tubular reactor section 202 when the solar reforming reactor 200 is in use. Each tubular reactor section 202 is also preferably respectively substantially radially aligned within a plane on that housing 250. [0071] The tubular reactor sections 202 may be any suitable configuration or shape. The preferred geometric configuration is to maximise capture of incident solar energy and to position the hydrocarbon inlet at maximum solar flux. [0072] Figures 5 to 7A show four different solar reformer reactors 200A, 200B, 200X and 200C that include acuate tubular reactor sections 202A, 202B, 202X and 202C. [0073] The solar reformer reactor 200A illustrated in Figure 5 includes two intercoiled spiral coil tubular reactor sections 202A. Each of the spiral coil tubular reactor sections 202A are wound as a planar coil about the common central axis X-X. In this embodiment, each of the water feed inlet 206A, product gas outlet 209A extends from the outer coil. The hydrocarbon feed inlet 208A extend into the center of the coil. Tubular solar reformer - first drait prove 17 [0074] The solar reformer reactor 200B illustrated in Figure 6 includes four intertwined single turn coil tubular reactor sections 202B. Each of the coil tubular reactor sections 202B are intertwined around the common central axis X-X and extend into and over a quarter segment of the hexagonal housing 250. The water feed inlet 206B, product gas outlet 209B and hydrocarbon feed inlet 208B are annularly spaced apart around the outer perimeter of the housing 25. [0075] The solar reformer reactor 200X illustrated in Figure 7 includes four intercoiled spiral coil tubular reactor sections 202X. Each of the spiral coil tubular reactor sections 202X are wound as a planar coil about the common central axis X-X. In this embodiment, the water feed inlet 206X extend from the outer coil, product gas outlet 209X. The hydrocarbon feed inlet 208X extends into the center of the coil. [0076] Figures 7A and 7B illustrates another solar reformer reactor 200C embodiment which includes four intertwined single turn coil tubular reactor sections 202C. Each of the tubular reactor sections 202C comprise U-shaped sections (best shown in the perspective view of one tubular reactor section 202C shown in Figure 7(B)) are spaced about and around the common central axis X-X, with the apex of each U-shaped section proximate the common central axis X-X. Again, the water feed inlet 206C, product gas outlet 209C and hydrocarbon feed inlet 208C are annularly spaced apart around the outer perimeter of the housing 250. [0077] Figure 8A to 10C show three different solar reformer reactors 200D, 200E and 200F that have linear tubular reactor sections 202D, 202E and 202F. [0078] Figures 8A and 8B illustrates a solar reformer reactor 200D embodiment which includes four linear tubular reactor sections 202D. Each of the tubular reactor sections 202D comprise straight pipe sections (best shown in the perspective view of one tubular reactor section 202D shown in Figure 8(B)) which extend through the common central axis X-X. The water feed inlet 206D, product gas outlet 209D and hydrocarbon feed inlet 208D are annularly spaced apart around the outer perimeter of the housing 250. The center of each tubular Tubular solar reformer - first drait prove 18 reactor section 202D may include a small arch or notch in the longitudinal center (in line with the common central axis X-X) in order to accommodate the overlap of an adjacent tubular reactor section 202D. It should be appreciated that further tubular reactor sections 202D may also be used to reduce the annular gap between adjacent tubular reactor sections 202D. [0079] Figures 9A and 9B illustrates a solar reformer reactor 200E embodiment which includes eight linear tubular reactor sections 202E. Each of the tubular reactor sections 202E comprise L-shaped pipe sections (best shown in the perspective view of one tubular reactor section 202E shown in Figure 9(B)) which extend through the common central axis X-X. The L-shape is formed by the hydrocarbon feed inlet 208E axially extending along the common central axis X-X into the center of the housing 250. The water feed inlet 206E and product gas outlet 209E are annularly spaced apart around the outer perimeter of the housing 250. Again, it should be appreciated that further tubular reactor sections 202E may also be used to reduce the annular gap between adjacent tubular reactor sections 202E. [0080] Figures 10A, 10B and 10C illustrates a solar reformer reactor 200F embodiment which includes eight linear tubular reactor sections 202F. Each of the tubular reactor sections 202F comprise L-shaped pipe sections (best shown in the perspective view of one tubular reactor section 202F and 202F* shown in Figure 101B) (circular cross-section wedge) and 10C (rectangular cross-section wedge)) which extend through the common central axis X-X. In this instance, the diameter of the tube in the reaction zone 215F increases radially outwardly from the common central axis. This section of each tubular reactor section 202F therefore forms an arc segment. Again, the L-shape is formed by the hydrocarbon feed inlet 208F axially extending along the common central axis X X into the center of the housing 250. The water feed inlet 206F and product gas outlet 209F are annularly spaced apart around the outer perimeter of the housing 250. Solar Reforming Reactor Operation Tubular solar reformer - first drait prove 19 [0081] Operation of one of the above described solar reforming reactors can require specialised catalyst activation, start-up, normal operation and shutdown procedures. The following describes one set of catalyst activation, start-up, normal operation and shutdown procedures for a solar reforming reactor according to the present invention. [0082] CATALYST ACTIVATION 1. Start circulation of hydrogen or product synthesis gas (syngas). 2. Heat each of the reformer reactor to 600C and m onitor the hydrogen in the product gas. 3. Maintain a reformer reactor temperature of around 600C by adjusting the solar energy input to the reformer reactor. 4. Catalyst activation is completed when the product gas flow rate has returned to starting level. This can be left for another hour before cooling down the r reformer reactor. [0083] START-UP 1. Start circulation of preheat gas which can be nitrogen, hydrogen or product syngas. Hydrogen or product syngas avoid product gas dilution and possible nitriding of the reformer and other heated pipes. The reformer should be controlled to less than 400C when using syngas without steam in order to avoid carbon deposition on the catalysts. 2. Start filling the inner pipe until the water reaches the water/steam inlet of the reformer. Water must not be fed past the end of the inner pipe to avoid damage to the catalyst. A pressure/level indicator can be used to indicate the position of water relative to the main water inlet. As a precaution, the amount of water needed at this stage must be calculated to estimate the initial water feed rates. 3. Start heating the reformer with preheat gas. 4. Once the reformer reaches a temperature which is 50C above the saturation temperature of water at the selected operating pressure, water can be introduced at a rate such that condensation in the reformer reactor can be Tubular solar reformer - first drait prove 20 avoided. Thermocouples can be used as an indicator as to when water has turned to steam in the inner pipe. [0084] REFORMING 1. Once the reformer reactor has reached desired operating temperatures, the feed gas is switched from preheat gas to a hydrocarbon gas to start the reforming process. 2. For maximum utilisation of available solar energy and a specified reformer capacity, the feed rates of methane-rich gas is adjusted such that (a) the maximum allowable pipe surface temperatures are not exceeded at all times, and (b) the minimum allowable reformer reactor temperature is not reached, being the temperature below which no reforming takes place. 3. The water feed rates should satisfy specific water:carbon ratios such that carbon formation is avoided. The control system can be configured such that this is always achieved by automatically adjusting either the methane-gas flow rates or water feed rates for maximum solar energy utilisation. [0085] SHUTDOWN 1. The reformer reactor is normally shutdown when available solar energy is below desired amounts. In this case, the feed rates of methane-rich gas can be increased further if faster cooling of the reformer reactor is desired. 2. The feed gas is switched from methane-rich gas to preheat gas once the reformer reactor temperature has dropped to around 5001C. 3. The solar energy input to the reformer reactor is slowly reduced. 4. Water feed to the reformer reactor is terminated as soon as reformer reactor temperatures falls just below a temperature that is about 1001C above the saturation temperature of the water, but not above about 3501C to avoid carbon deposition. 5. The reformer reactor is allowed to cool down under a flow of preheat gas. 6. For emergency shutdown, above steps are followed whenever possible in order to avoid damage to the catalyst and reformer pipes. Control system Tubular solar reformer - first drait prove 21 [0086] The present invention has particular utility when used in combination with a central receiver solar energy collection system utilising a combination of closed and open loop control and calibration. Such a system 10 is depicted in Figures 1, 2 and 11. [0087] An optimally receiving position for this system 10 is the angular position of the heliostat determined by a central controller, discussed further below, to be the appropriate position at the particular time on the particular date at which the respective heliostat makes a desired contribution to the energy flux incident on the receiver target 13. In general, the objective is to best approximate the desired flux levels and flux distribution at the receiver 12. [0088] Receiver 12 hangs downwardly from a supporting cantilever framework 19 fixed to tower 11. Also fitted to framework 19, by being suspended between a pair of inclined struts 31, is a secondary or auxiliary target 30 (Figure 2). The secondary target 30 is, in this case, spaced from the primary target aperture 13 and disposed so as not to be intercepted by the optimally received and directed beams of light from the heliostats 15. In this embodiment, the secondary target 30 is a highly reflective rectangular surface on which is trained a camera 35. Camera 35 is mounted on the ground below the receiver 12 at the position indicated in Figure 12, and is designed to record a two-dimensional flux image representative of a cross-section of any sunlight beam that impinges on the secondary target 30. [0089] Each heliostat 15, has an individual actuator system 21 typically comprising a pair of linear actuators 60, 62 (Figure 12) for respectively controlling the inclination and declination of the heliostat's 15 reflecting surface. The angular position of each heliostat 15, both inclination and declination, is determined by a central controller 40 (Figure 12) which may comprise a suitable computer system. This controller 40 is operably coupled to the actuators 60, 62 of all of the heliostats 15, to magnetic sensors 80 by which the controller 40 is kept informed of the actual angular position co-ordinator of each heliostat 15, and to camera 35. As well as activating and deactivating the system 10 into Tubular solar reformer - first drait prove 22 and out of operation, controller 40 is programmed to carry out a number of calibration and control tasks in order to optimise the convertible energy received at primary target aperture 13. [0090] An example of a functional small field central receiver solar energy collection system of the type depicted in Figures 1, 2 to 11 and 12 is a close packed field of 170 heliostats 15 of rectangular shape measuring about 2.4 metres by 1.84 metres and having a shallow concave reflecting surface with focal lengths between 15 and 38 metres, according to their position in the field. The field is designed for maximum annual energy collection by a receiver aperture 13 of diameter 0.8m at an elevation of 17 metres at an angle of 17 0 to the horizontal. In an alternative arrangement there may be two receivers with associated apertures to which respective halves of the field 18 are focused during operation. [0091] In this context "maximum energy collection" refers to maximising the energy during early morning and late afternoon times when one is typically using nearly 100% of the field to achieve the desired power level. The term also refers to how much light gets through the aperture 13, which is the total light reflected by the mirror minus the light hitting the shield around the aperture: the better the mirror of the heliostat 15 is aimed, the less light is lost on the heat shield and more light gets through the aperture 13. [0092] Figure 13 is a photo of the secondary target 30 bearing a representative flux image of a heliostat-reflected beam as it would be observed at secondary target 30 by camera 35. It can visually be seen that the energy flux centre (marked by the crosshairs) of the flux image is geometrically off-centre. The controller 40 utilises any suitable known analytic tool to derive a geometric location of this centre, or centroid, of the flux image, and from this determines a correcting offset for the angular position of the respective heliostat 15. [0093] Repetition of this process across all heliostats 15 in turn during operation of the apparatus constitutes an "instantaneous" calibration of each heliostat 15 Tubular solar reformer - first drait prove 23 and thus assists in real time optimisation of the focus of the reflected beams of sunlight 102 onto the primary target aperture 13. Moreover, the arrangement is effective to improve the accuracy of receipt of the beam of sunlight 100 and direction of the reflected beam 102 to the primary target 13, and so to compensate, by closed loop control during operation of the apparatus, for tolerances in heliostat 15 and actuator geometries. It is preferred that calibration is continuously performed during solar plant operation by a controller managed program of sequentially taking each heliostat 15 off primary target, directing its reflected beam 102 to the secondary target 30, calibrating the heliostat 15, and adjusting its position to optimise the heliostat's 15 contribution to the receiver aperture 13. [0094] The flux image acquired by way of the camera 35 is also employed to calibrate a model of the heliostat geometry. The aforedescribed calibration measurements for each heliostat 15 are taken at multiple time points over a day whereby to acquire a set of offsets. As just described, these offsets are used each time to offset the actuator, and thereby heliostat 15, positions to cause the respective beams 102 to be more accurately located in the primary target aperture 13. Closed loop control of heliostat 15 position is thereby achieved. Any errors in the modelled geometry will cause small errors as the beam 102 is moved back from the secondary target 30 to the receiver primary target aperture 13. The target offsets can be employed to calibrate the geometry errors (over a longer time scale) and once the geometry errors have been calibrated out, the average offset position will be close to zero. The combination of open loop (from calibrations) and closed loop (from offsets) positioning results in highly accurate tracking, allowing compensation for the employment of inexpensive heliostat actuation fabrication methods, and for the consequent substantial tolerances in heliostat 15 and actuator geometries. [0095] To develop a calibration model, model equations are formed that describe the effect of misalignments as a function of heliostat 15 and therefore sun position. These misalignments include rotation of the primary axis away from true east-west, tilt of the primary axis from horizontal, and deviation from Tubular solar reformer - first drait prove 24 orthogonality between the pivot axes. The linear actuator geometry is formed by a triangle with two fixed sides and one side of variable length, so that three parameters (side A, side B and side C with actuator fully retracted) are sufficient to describe each actuator geometry. With the XYZ position of each mirror there are twelve calibration terms in all. Persons skilled in the art will appreciate that it is possible to perform coordinate rotations and combinations to reduce the dimensions of the model: it is found that seven of these twelve terms can be measured directly leaving five terms to be determined experimentally. In fact, in accordance with the preferred practice of this invention, three measurements over 4 hourly intervals repeated at 3-monthly intervals are sufficient to determine the unknown calibration constants. The preferred method for this purpose is to use a weighted and constrained gradient descent method, although those skilled in the art will appreciate that any of the standard non linear or linearised regression methods may be employed. [0096] During commissioning there is insufficient data over a time scale of months to accurately determine all constants, so the less well determined parameters are given low weights and tight constraints initially. The closed loop positioning method provides reasonable accuracy until enough months have elapsed to traverse sufficient calibration space to obtain an accurate calibration model. [0097] These concepts are elaborated upon diagrammatically in Figure 14. Here, the discs S1 and S2 on the primary and second targets 13, 30 represent current image zones in which a selected percentage of the heliostat 15 reflected energy is found. The image observed by the camera may be employed to determine an offset to adjust the relative positions on the targets and is also fed to the calibration model 50 for the respective heliostat. This diagram demonstrates the continuous closed loop control employed during normal operation of the central receiver solar energy collection system incorporating sequential adjustment of each heliostat to direct its reflected beam to the secondary target. Tubular solar reformer - first drait prove 25 [0098] The control system may have the ability to control the target reforming reactor temperature range through regulating the mass flow rate of the reactant mixture within a solar reforming reactor according to the present invention. Further details regarding the control and calibration system may be found in patent application PCT/AU2011/001687. [0099] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope of the present invention. [00100] Where the terms "comprise", "comprises", "comprised" or "comprising" are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other feature, integer, step, component or group thereof. Tubular solar reformer - first drait prove
    权利要求:
    Claims (20)
    [1] 1. A solar reforming reactor for reforming a reactant mixture comprising a hydrocarbon fuel at a target reforming temperature to produce synthesis gas, the reforming reactor comprising a plurality of elongate tubular reactor sections arranged about a common central axis, each tubular reactor section being arranged to extend about and/or around the common central axis.
    [2] 2. A solar reforming reactor according to claim 1, wherein the reactor comprises an inner tube housed within an outer tube.
    [3] 3. A solar reforming reactor according to claim 2, further comprising a reforming catalyst located in the inner tube or between the outer tube and the inner tube.
    [4] 4. A solar reforming reactor according to any one of the preceding claims, wherein the reforming reactor comprises at least three elongate tubular reactor sections arranged about the common central axis.
    [5] 5. A solar reforming reactor according to any preceding claim, wherein the tubes of each respective tubular reactor section are arranged in an intertwined or overlapping arrangement about the common axis.
    [6] 6. A solar reforming reactor according to any preceding claim, wherein each tubular reactor section has an reactant feed inlet, each inlet being evenly annularly spaced apart about the common central axis.
    [7] 7. A solar reforming reactor according to any one of claims 1 to 6, wherein each tubular reactor section includes at least one linear section, each linear section being configured to extend radially through or about the common central axis. Tubular Sola refolmgr - isi diafi ploV 27
    [8] 8. A solar reforming reactor according to any preceding claim, wherein the cross-sectional size of at least one of the outer tube or each of the outer tube and inner tube increases radially outwardly from the common central axis.
    [9] 9. A solar reforming reactor according to any preceding claim, further comprising a first reactant inlet which extends, preferably axially extends relative to the common central axis, into the geometric center of the layout of the outer and inner tubes.
    [10] 10. A solar reforming reactor according to any preceding claim, further comprising a second reactant inlet that extends radially outwardly towards the outer perimeter of the layout of the outer and inner tubes relative to the common central axis.
    [11] 11. A solar reforming reactor according to any preceding claim, wherein the tubes of each tubular reactor section are laid out within a housing which has a central axis extending through the common central axis of the at least two tubular reactor sections.
    [12] 12. A solar reforming reactor according to claim 11, wherein the housing has an axial cross-sectional shape relative to the axis comprising a circle or polygon, preferably a regular polygon, and more preferably a hexagon.
    [13] 13. A solar reforming reactor according to any preceding claim, wherein each tubular reactor section includes: an outer tube having a first end and a second end, the second end being axially spaced apart from the first end along the longitudinal length of the outer tube; at least one inner tube, the inner tube being housed within the outer tube and extending within the outer tube from the first end to a mixing location within the outer tube, the mixing location being longitudinally spaced away from the second end; a catalyst which longitudinally extends within the solar reforming reactor between the mixing location and first end of the outer tube, the catalyst being Tubular Sola rfolm r - ilsi dai plcV 28 located either in a first arrangement in which the catalyst is housed within the inner tube; or a second configuration in which the catalyst is housed between the inner tube and outer tube.
    [14] 14. A solar reforming reactor according to claim 13, wherein, in use, the reactants are fed countercurrently into each tubular reactor section.
    [15] 15. A solar reforming reactor according to any preceding claim, wherein the reactants comprise: a first reactant comprising at least one hydrocarbon species, the first reactant being fed into each tubular reactor section to flow from the second end of the outer tube to the mixing location; and a second reactant comprising at least one of water, carbon monoxide or carbon dioxide, the second reactant being fed into each tubular reactor section to flow from the first end of the outer tube to the mixing location either between an inner tube and the outer tube when the catalyst is in the first arrangement or through the inner tube when the catalyst is in the second arrangement.
    [16] 16. A solar reforming reactor according to claim 15, wherein the catalyst axially extends within the solar reforming reactor between the mixing location and a reaction termination location, the reaction termination location being longitudinally spaced away from the first end of the outer tube of each tubular reactor section.
    [17] 17. A solar reforming reactor according to claim 16, wherein the reaction termination location is spaced longitudinally remotely away from the first end of the outer tube to provide a heat transfer zone for heat transfer between components flowing between the outer and inner tube and components flowing in the inner tube.
    [18] 18. A solar reforming reactor according to any one of claims 15 to 17, including a plurality of inner tubes, the catalyst being housed between the inner tube and outer tube and also in alternating concentric cavities between each Tubular Sola rcfolmgr - ilsi dai plcV 29 concentric inner tube, the second reactant feed flowing from the first end of the outer tube to the mixing location in the respective alternate concentric cavities to the catalyst between each concentric inner tube.
    [19] 19. An apparatus for the production of synthesis gas comprising: a plurality of heliostats; and a solar energy receiver for receiving solar energy directed thereon from the heliostats and transferring said energy to a reforming reactor according to any one of the preceding claims.
    [20] 20. The apparatus according to claim 19, wherein the control system calibrates the thermal flux of the solar energy receiver, and wherein the solar energy receiver defines a primary target to receive directed sunlight from a field of heliostats each mounted for angular adjustment to optimally receive a beam of sunlight and direct it to the primary target of the solar energy receiver, the receiver is calibrated through the steps comprising: during operation of the solar energy apparatus, sequentially causing a temporary angular adjustment of the respective said heliostats so as to divert the beam of sunlight received at each heliostat to a secondary target for a predetermined period of time, which secondary target is at or spaced from the primary target and disposed so as not to be intercepted by said optimally received and directed beams of sunlight, thereafter returning the heliostat to a position in which the received beam of sunlight is directed to the primary target, recording a representation of each directed beam at the secondary target; responding to the representation of the diverted beam for the respective heliostats when a parameter or element thereof deviates from a reference norm, by angularly adjusting the corresponding heliostat to improve the accuracy of its receipt of said beam of sunlight and direction of the beam to the primary target, thereby compensating by closed loop control of the field of heliostats during operation of the apparatus for tolerances in heliostat and actuator geometries; and Tubular Sola refolmgr - ilsi diafi pov 30 causing a said representation to be acquired for each of multiple heliostats at different times over a day and over an extended period of multiple days and for corresponding angular positions of the heliostat, whereby to obtain a calibration model for the heliostats with respect to multiple time points as well as the geometry of the heliostats, and whereby to achieve a combination of open loop and closed loop control of the positions of the heliostats. Tubular Sola rcfon r - ilsi dai plcV
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    同族专利:
    公开号 | 公开日
    AU2013206238B2|2017-10-19|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US20090277442A1|2008-05-10|2009-11-12|Reed Jensen|Coiled heat exchanger with beam spreader especially for use with solar-powered gas processors|
    法律状态:
    2018-02-15| FGA| Letters patent sealed or granted (standard patent)|
    优先权:
    申请号 | 申请日 | 专利标题
    AU2012902596||2012-06-20||
    AU2012902596A|AU2012902596A0||2012-06-20|Solar Reforming Reactor|
    AU2013206238A|AU2013206238B2|2012-06-20|2013-06-07|Solar Reforming Reactor|AU2013206238A| AU2013206238B2|2012-06-20|2013-06-07|Solar Reforming Reactor|
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