(363an) Reactor and Processes for Endothermic Reactions at High Temps Basis for the Next Generation of Styrene Monomer Plants

A common way for styrene producers and others to provide the energy for high temperature endothermic catalytic reactions is to mix superheated steam with the reactants over a catalyst bed. Collisions between superheated steam molecules and the organic reactants and products account for much of the resultant byproduct formation. Instead of decarbonizing these byproducts, an alternative is to avoid forming them. The process described here includes a radiant furnace with a burner adapted to provide thermal energy to the furnace and a cylindrical reactor that includes one or more static helical spirals defining a flow path within the reactor. The helical spirals are adapted to hold a catalyst on both sides. This process can be used for the conversion of ehylbenzene (EB) to styrene monomer at a temperature between 650 and 700 degrees Celsius. It offers several advantages over existing commercial processes, including the elimination of the flow resistance of a catalyst bed, reduced byproduct formation, significantly higher EB conversion, and lower high temperature demand.