Catalytic reactor designed to reduce catalyst slumping and crushing

摘要

A steam reformer for converting a reactor fuel into a product gas includes a segmented catalyst bed. The steam reformer side walls have a thermal coefficient of expansion which is greater than the thermal coefficient of expansion of the catalyst. By forming low volume catalyst bed segments in the hotter portions of the catalyst bed, slumping and subsequent damage of the catalyst pellets is minimized. The catalyst bed is divided into segments whose volumes are inversely proportional to the temperatures of the various zones in the reformer. The segments are formed by utilizing sequential catalyst support assemblies which include perforated catalyst support members that are differentially spaced apart from each other by support assembly legs having varying lengths. Catalyst support assemblies with shorter length legs are used in the hotter zones of the reformer, and support assemblies with progressively longer length legs are used in the cooler zones of the reformer.