System and Method for Producing Chemicals at High Temperature

Abstract

A system for producing chemicals, such as, ethylene or gasoline, at high temperature (above 1100 degrees C.) having a feedstock source. The system includes a chemical conversion portion connected with the feedstock source to receive feedstock and convert the feedstock to ethylene or gasoline. The conversion portion includes a coil array and a furnace that heats the feedstock to temperatures in excess of 1100° C. or 1200° C. or even 1250° C. or even 1300° C. or even 1400° C. A method for producing chemicals, such as ethylene or gasoline, at high temperature.

1 . A method for producing ethylene or gasoline comprising the steps of:
 flowing feedstock from a feedstock source to a chemical conversion portion connected with the feedstock source to receive feedstock and convert the feedstock to ethylene or gasoline, the conversion portion including a coil array and a furnace that heats the feedstock to temperatures in excess of 1100° C., the coil array having a plurality of coils, each coil having a right top portion made of super alloy that connects with the source to receive feedstock, a right oxidation protected tungsten coupling that is attached outside the furnace to the right top portion and forms a helium gas tight seal with the right top portion, a right bottom portion made of silicon carbide that is attached outside the furnace to the right oxidation protected tungsten coupling and forms a helium gas tight seal with the right oxidation protected tungsten coupling, a base made of silicon carbide that is attached to the right bottom portion and forms a helium gas tight seal with the right bottom portion, a left bottom portion made of silicon carbide that is attached to the base and forms a helium gas tight seal with the base, a left oxidation protected tungsten coupling that is attached outside the furnace to the left bottom portion and forms a helium gas tight seal with the left bottom portion, and a left top portion made of super alloy that is attached to the left oxidation protected tungsten coupling outside the furnace and forms a helium gas tight seal with the left oxidation protected tungsten coupling, the right top portion and the right oxidation protected tungsten coupling and the right bottom portion and the base and the left bottom portion and the left oxidation protected tungsten coupling and the left top portion being hollow and defining a channel through which feedstock flows and is heated by the furnace to produce ethylene or gasoline from the feedstock, the furnace heating the left bottom portion and the base and the right bottom portion to temperatures in excess of 1100° C.; and   receiving ethylene or gasoline at a reservoir from the left top portion of each coil.   
     
     
         2 . A method for forming an assembly comprising the steps of:
 placing a first tube of silicon carbide or mullite or superalloy adjacent a second tube of silicon carbide or mullite or tungsten; and bonding with a helium leak tight seal the first and second tubes together, the helium leak tight seal maintains its integrity at a temperature of greater than 1100° C.   
     
     
         3 . The method of  claim 2  wherein the bonding step includes the step of forming a mixed oxide joint, or braze joint between the first tube and second tube. 
     
     
         4 . The method of  claim 2  wherein the forming step includes applying a mixture of between 30 wt % (weight percent or percent by mass) and 80 wt % alumina-silicate and between 20 wt % and 70 wt % magnesia-silicate in powder form to a 100% weight between the first and second tubes; or a mixture of between 80-10 wt % 80/20 nickel chromium alloy and 20-90 wt % copper of ≥99.99% purity together to form a 100% weight. There is the step of mixing the nickel chromium alloy and the copper to form an alloy that is then nominally 33 wt % of 80/20 nickel-chromium and 67 wt % copper. 
     
     
         5 . A method for making a mixture for a joint between ceramic tubes or ceramic tubes and metal tubes comprising the steps of:
 putting between 30 wt % (weight percent or percent by mass) and 80 wt % alumina-silicate and between 20 wt % and 70 wt % magnesia-silicate together in powder form to a 100% weight; and mixing the alumina-silicate and magnesia-silicate together.   
     
     
         6 . A pipe structure for use at high temperatures:
 a first tube of silicon carbide extending in a first direction; and a second tube of silicon carbide extending from the first tube, wherein the first and second tubes are bonded with a helium leak tight seal.   
     
     
         7 . The pipe structure of  claim 6  wherein the second tube extends in a second direction substantially perpendicular to the first direction. 
     
     
         8 . The pipe structure of  claim 6  further comprising a metal buffer tube extending from the first tube, wherein the first tube and the metal buffer tube are bonded with a helium leak tight. 
     
     
         9 . The pipe structure of  claim 8  further comprising a superalloy tube extending from the metal buffer tube, wherein the superalloy tube and the metal buffer tube are bonded with a helium leak tight seal. 
     
     
         10 . The pipe structure of  claim 6  further comprising a first plug of silicon carbide inserted into the second tube of silicon carbide, wherein the first plug and the second tube are bonded with a helium leak tight seal. 
     
     
         11 . The pipe structure of  claim 10  further comprising a second plug of silicon carbide inserted into the second tube of silicon carbide, wherein the second plug and the second tube are bonded with a helium leak tight seal. 
     
     
         12 . The pipe structure of  claim 6  further comprising a third tube of silicon carbide extending in the first direction, wherein the third tube and the second tube are bonded with a helium leak tight seal. 
     
     
         13 . The pipe structure of  claim 12  wherein the second tube extends in a second direction substantially perpendicular to the first direction. 
     
     
         14 . The pipe structure of  claim 12  wherein the second tube has a rectangular perimeter.