Electrically Heated Reactor

Abstract

An electrically heated reactor is disclosed, comprising at least one first reaction tube having a first passage formed therein for reactants to pass through and configured to heat the reactants passing through the first passage, at least one second reaction tube having a second passage formed therein for reactants to pass through and configured to heat the reactants passing through the second passage, a first power source configured to supply power to the at least one first reaction tube, and a second power source configured to supply power to the at least one second reaction tube, wherein the first power source and the second power source can be independently controlled.

Description

[Technical Field]

[0001] [Cross-reference to related applications] This application claims the benefit of priority based on Korean Patent Application No. 10-2023-0074916 filed June 12, 2023 and Korean Patent Application No. 10-2024-0075968 filed June 11, 2024, and all contents disclosed in the documents of said Korean patent applications are incorporated herein by reference.

[0002] The present invention relates to an electrically heated reactor, and more particularly to an electrically heated reactor in which the interior of a reactor housing is divided into a plurality of reaction zones, and each reaction zone is independently heated using electrical heating technology. [Background technology]

[0003] In the chemical industry, natural gas is used as fuel to maintain high temperatures in various equipment (e.g., crackers, reformers, reactors, boilers, etc.). However, heating by burning natural gas is not only inefficient in terms of energy consumption, but is also a major source of carbon emissions. Therefore, efforts are being made to replace heating by burning natural gas with electric heating.

[0004] The matters described in this background art section are prepared to enhance understanding of the background of the invention, and may include matters that are not conventional art already known to those having ordinary skill in the art to which this technology pertains. Summary of the Invention [Problem to be solved by the invention]

[0005] An embodiment of the present invention aims to provide an electrically heated reactor in which the interior of the reactor housing is divided into multiple reaction zones, and each reaction zone is independently heated using electrical heating technology. [Means for solving the problem]

[0006] An electrically heated reactor according to one embodiment of the present invention includes at least one first reaction tube having a first passage formed therein through which reactants pass and configured to heat the reactants passing through the first passage; at least one second reaction tube having a second passage formed therein through which reactants pass and configured to heat the reactants passing through the second passage; a first power source configured to supply power to the at least one first reaction tube; and a second power source configured to supply power to the at least one second reaction tube, wherein the first power source and the second power source can be independently controlled.

[0007] The first passageway can define a first reaction zone and the second passageway can define a second reaction zone.

[0008] The electrically heated reactor may further include a first reactor inlet connected to the first reaction zone to supply reactants to the first reaction zone; a first reactor outlet connected to the first reaction zone to discharge reactants from the first reaction zone; a second reactor inlet connected to the second reaction zone to supply reactants to the second reaction zone; and a second reactor outlet connected to the second reaction zone to discharge reactants from the second reaction zone.

[0009] In an electrically heated reactor, the first and second reaction zones may not communicate with each other.

[0010] In one example, the electrically heated reactor can further include a first mixer configured to receive and mix a first type of reactants from a first type of reactant source and deliver the mixed first type of reactants to a first reaction tube; and a second mixer configured to receive and mix the first type of reactants from the first type of reactant source and deliver the mixed first type of reactants to a second reaction tube.

[0011] The first and second reaction zones are controlled to the same temperature, and the first and second reaction zones are supplied with the first reactant from the first and second mixers, respectively, so that the same reaction can occur in the first and second reaction zones.

[0012] In another example, the electrically heated reactor can further include a first mixer configured to receive and mix a first type of reactants from a first type of reactant source and deliver the mixed first type of reactants to the first reaction tube; and a second mixer configured to receive and mix a second type of reactants from a second type of reactant source and deliver the mixed second type of reactants to the second reaction tube.

[0013] The first and second reaction zones are controlled to different temperatures, and a first type of reactant is supplied to the first reaction zone from a first mixer, and a second type of reactant is supplied to the second reaction zone from a second mixer, allowing different reactions to occur simultaneously.

[0014] At least one first reaction tube and at least one second reaction tube are arranged longitudinally within a reactor housing, and a partition wall is installed longitudinally within the reactor housing to physically divide the space within the reactor housing into first and second zones, with at least one first reaction tube being arranged in the first zone and at least one second reaction tube being arranged in the second zone.

[0015] The electrically heated reactor may further include an insulator that surrounds at least a portion of the first and second reaction tubes to provide thermal insulation therefrom. [Effects of the Invention]

[0016] According to the present invention, electrical heating technology can be utilized to efficiently and uniformly maintain the temperature within the reactor.

[0017] In addition, the inside of the reactor housing can be divided into multiple reaction zones, and each reaction zone can be heated independently, allowing a single electrically heated reactor to support various reactions and produce various products.

[0018] Other advantages achieved or expected by the embodiments of the present invention are directly or implicitly disclosed in the detailed description of the embodiments of the present invention, i.e., various advantages expected by the embodiments of the present invention are disclosed in the detailed description below.

[0019] The embodiments herein may be better understood by reference to the following description in conjunction with the accompanying drawings, where like reference numbers indicate identical or functionally similar elements and wherein: [Brief explanation of the drawings]

[0020] [Figure 1] 1 is a schematic cross-sectional view showing an electrically heated reactor according to an embodiment of the present invention. [Figure 2] 1 is a plan view showing a cross section of an electrically heated reactor according to an embodiment of the present invention. [Figure 3] 1 illustrates an example of using an electrically heated reactor according to an embodiment of the present invention. [Figure 4] 10 shows another example of using an electrically heated reactor according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0021] The above-referenced drawings are not necessarily drawn to scale and should be understood as depicting somewhat simplified representations of various preferred features illustrating the underlying principles of the present disclosure. Specific design features of the present disclosure, including, for example, specific dimensions, orientations, locations, and shapes, are determined in part by the particular intended application and use environment.

[0022] The terms used herein are for the purpose of describing particular embodiments and are not intended to limit the present invention. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise. It will also be understood that, as used herein, the terms "comprises" and / or "comprises" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term "and / or" includes any one or all combinations of the associated listed items.

[0023] It is further understood that the methods described below, or one or more of their aspects, can be performed by at least one or more controllers. The term "controller" can refer to a hardware device including a memory and a processor. The memory is configured to store program instructions, and the processor is specifically programmed to execute the program instructions to perform one or more processes described in more detail below. The controller can control the operation of a unit, module, component, device, or the like, as described herein. It is also understood that the methods described below can be performed by a device that includes a controller along with one or more other components, as will be appreciated by those skilled in the art.

[0024] The controller of the present disclosure may also be embodied as a non-transitory computer-readable storage medium containing executable program instructions for execution by a processor. Examples of computer-readable storage media include, but are not limited to, ROM, RAM, compact disc (CD) ROM, magnetic tape, floppy disk, flash drive, smart card, and optical data storage device. The computer-readable storage medium may also be distributed across a computer network so that the program instructions are stored and executed in a distributed manner, such as in a telematics server or controller area network (CAN).

[0025] According to the present invention, an electrically heated reactor includes at least one first reaction tube having a first passage formed therein through which reactants pass and configured to heat the reactants passing through the first passage, at least one second reaction tube having a second passage formed therein through which reactants pass and configured to heat the reactants passing through the second passage, a first power source configured to supply power to the at least one first reaction tube, and a second power source configured to supply power to the at least one second reaction tube. Thus, the present invention utilizes electric heating technology to efficiently and uniformly maintain a temperature within the reactor.

[0026] Furthermore, the first and second power sources can be controlled independently, i.e., the supply of power to the first reaction region defined by the first passage and the supply of power to the second reaction region defined by the second passage can be controlled independently of each other.

[0027] Additionally, the first and second reaction regions can be controlled to different temperatures. If the first and second reaction regions are controlled to the same temperature, the same type of reactant can be supplied to the first and second reaction regions, thereby expanding the reaction region. Alternatively, if the first and second reaction regions are controlled to different temperatures, a first type of reactant can be supplied to the first reaction region and a second type of reactant can be supplied to the second reaction region, thereby allowing different reactions to proceed within a single reactor. Therefore, a single electrically heated reactor can support various reactions and produce a variety of products.

[0028] In one example, the electrically heated reactor may further include a first mixer configured to receive and mix a first type of reactant from a first type of reactant source and supply the mixed first reactant to the first reaction tube, and a second mixer configured to receive and mix a second type of reactant from a second type of reactant source and supply the mixed second reactant to the second reaction tube. Thus, in the first reaction zone, the first reactant is controlled at a first temperature to cause a first reaction and produce a first product, and in the second reaction zone, the second reactant is controlled at a second temperature to cause a second reaction and produce a second product.

[0029] The electrically heated reactor further includes an insulator that surrounds and thermally insulates the first and second reaction tubes, thereby reducing unnecessary heat loss to the outside of the electrically heated reactor and improving energy efficiency.

[0030] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0031] FIG. 1 is a schematic cross-sectional view showing an electrically heated reactor according to an embodiment of the present invention, and FIG. 2 is a plan view showing a cross section of an electrically heated reactor according to an embodiment of the present invention.

[0032] 1 and 2, an electrically heated reactor 10 according to an embodiment of the present invention is configured to generate heat when supplied with electric power and to heat reactants therein using the generated heat. The electrically heated reactor 10 includes a reactor housing 11, at least one first reaction tube 20, and at least one second reaction tube 30.

[0033] The reactor housing 11 is formed in a generally cylindrical shape, and a partition wall 19 is installed inside the reactor housing 11 in the longitudinal direction, physically dividing the space inside the reactor housing 11 into two zones. Therefore, the first zone and the second zone do not communicate with each other inside the reactor housing 11. The first zone is provided with at least one first reaction tube 20, and the second zone is provided with at least one second reaction tube 30.

[0034] A first reactor inlet 12 connected to the first zone is formed on one side of the reactor housing 11, and a first reactor outlet 14 connected to the first zone is formed on the other side of the reactor housing 11. The first reactor inlet 12 and the first reactor outlet 14 are fluidly connected to a first reaction tube 20, and reactants flowing into the first zone of the reactor housing 11 through the first reactor inlet 12 pass through the first reaction tube 20, are electrically heated, and then are discharged out of the first zone of the reactor housing 11 through the first reactor outlet 14. Here, the reactants are electrically heated in the first reaction tube 20, and the region within the first reaction tube 20 where the desired reaction can occur is referred to as a first reaction zone 24.

[0035] In addition, a second reactor inlet 16 connected to the second zone is formed on one side of the reactor housing 11, and a second reactor outlet 18 connected to the second zone is formed on the other side of the reactor housing 11. The second reactor inlet 16 and the second reactor outlet 18 are fluidly connected to a second reaction tube 30, and reactants flowing into the second zone of the reactor housing 11 through the second reactor inlet 16 pass through the second reaction tube 30, are electrically heated, and then are discharged out of the second zone of the reactor housing 11 through the second reactor outlet 18. Here, since the reactants are electrically heated in the second reaction tube 30 and the target reaction can occur, the region within the second reaction tube 30 is referred to as the second reaction zone 34.

[0036] Meanwhile, the first reaction region 24 and the second reaction region 34 do not communicate with each other inside the reactor housing 11, but may communicate with each other outside the reactor housing 11. More specifically, reactants that flow into the first reaction region 24 through the first reactor inlet 12 do not flow from the inside of the reactor housing 11 into the second reaction region 34, but are discharged to the outside of the reactor housing 11 through the first reactor outlet 14. Similarly, reactants that flow into the second reaction region 34 through the second reactor inlet 16 do not flow from the inside of the reactor housing 11 into the first reaction region 24, but are discharged to the outside of the reactor housing 11 through the second reactor outlet 18.

[0037] Furthermore, the number of partitions 19, the number of zones inside the reactor housing 11, and the number of types of reaction tubes are not limited to one, two, and two, respectively. Those skilled in the art can appropriately set the number of partitions 19, the number of zones inside the reactor housing 11, and the number of types of reaction tubes as needed.

[0038] The first reaction tube 20 is disposed in the first region and is made of a metal material having high resistivity. A first passage through which the reactants pass is formed in the first reaction tube 20 along its length. For example, the first reaction tube 20 may be formed in the shape of a circular pipe, with the first passage formed in the first reaction tube 20 along its length. When power is applied to the first reaction tube 20, the first reaction tube 20 generates heat due to its high resistivity, and the heat can heat the reactants in the first passage. Therefore, the first passage defines a first reaction region 24 where the reaction of the reactants occurs.

[0039] One end of the first reaction tube 20 closest to the first reactor inlet 12 defines a first tube inlet 21, and the other end of the first reaction tube 20 closest to the first reactor outlet 14 defines a first tube outlet 22. Reactants flowing into the reactor housing 11 through the first reactor inlet 12 flow into the first reaction tube 20 through the first tube inlet 21 and pass through a first reaction region 24 defined by a first passage, where they are electrically heated and the desired reaction occurs. The reactants reacted in the first reaction region 24 are discharged to the outside of the reactor housing 11 through the first tube outlet 22 and the first reactor outlet 14.

[0040] The second reaction tube 30 is disposed in the second region and is made of a metal material with high resistivity. A second passage for the reactants to pass through is formed in the second reaction tube 30 along its length. For example, the second reaction tube 30 may be formed in the shape of a circular pipe with a second passage formed in the second reaction tube 30 along its length. When power is applied to the second reaction tube 30, the second reaction tube 30 generates heat due to its high resistivity, and the heat can heat the reactants in the second passage. Therefore, the second passage defines a second reaction region 34 where the reaction of the reactants occurs.

[0041] One end of the second reaction tube 30, closer to the second reactor inlet 16, defines a second tube inlet 31, and the other end of the second reaction tube 30, closer to the second reactor outlet 18, defines a second tube outlet 32. The reactants flowing into the reactor housing 11 through the second reactor inlet 16 flow into the second reaction tube 30 through the second tube inlet 31, pass through a second reaction region 34 defined by a second passage, and are electrically heated to cause the desired reaction. The reactants reacted in the second reaction region 34 are discharged to the outside of the reactor housing 11 through the second tube outlet 32 ​​and the second reactor outlet 18.

[0042] The first power source 40 is configured to supply power to the first reaction tubes 20. That is, the first power source 40 is electrically connected to all of the first reaction tubes 20 and can supply the same amount of power to all of the first reaction tubes 20. The first power source 40 may be an AC power source or a DC power source.

[0043] The second power source 42 is configured to supply power to the second reaction tubes 30. That is, the second power source 42 is electrically connected to all of the second reaction tubes 30 and can supply the same amount of power to all of the second reaction tubes 30. The second power source 42 may be an AC power source or a DC power source.

[0044] The first power source 40 and the second power source 42 can be controlled independently. In particular, the magnitude of the power supplied from the second power source 42 to the second reaction tube 30 may be different from the magnitude of the power supplied from the first power source 40 to the first reaction tube 20. As a result, the temperatures of the first reaction region 24 and the second reaction region 34 may be controlled differently, and the reactions occurring in the first reaction region 24 and the second reaction region 34 may be different.

[0045] Sockets (not shown) are attached to one and the other ends of the first reaction tube 20, and a first power source 40 can supply power to the first reaction tube 20 through the sockets. Similarly, sockets (not shown) are attached to one and the other ends of the second reaction tube 30, and a second power source 42 can supply power to the second reaction tube 30 through the sockets. Each of the sockets is also attached with a cooling device, so that the sockets can be cooled.

[0046] The insulator 50 thermally insulates at least a portion of the first and second reaction tubes 20 and 30. As shown in Fig. 2, the insulator 50 may completely surround the first and second reaction tubes 20 and 30, but is not limited to this and may only partially surround the first and second reaction tubes 20 and 30. Because the insulator 50 thermally insulates the first and second reaction tubes 20 and 30, unnecessary heat loss that is discarded outside the first and second reaction tubes 20 and 30 is reduced, thereby improving energy efficiency and efficiently maintaining a uniform temperature inside the first and second reaction tubes 20 and 30.

[0047] In addition, the insulator 50 electrically isolates the first and second reaction tubes 20 and 30 from the outside, thereby preventing safety accidents that may occur due to current flowing through the first and second reaction tubes 20 and 30.

[0048] 3 shows an example of using an electrically heated reactor according to an embodiment of the present invention. In one example, but not limited to, a first reactant supply source 60 is configured to supply steam, a second reactant supply source 62 is configured to supply naphtha, and a third reactant supply source 64 is configured to supply ethane. FIG. 3 illustrates a case where the first reaction zone 24 and the second reaction zone 34 are controlled to the same temperature and naphtha steam cracking occurs in both the first reaction zone 24 and the second reaction zone 34.

[0049] As shown in FIG. 3 , the electrically heated reactor 10 further includes a first mixer 70 configured to receive and mix a first reactant from at least one of the first, second, and third reactant sources 60, 62, and 64, and supply the mixed first reactant to the first reaction tube 20, and a second mixer 72 configured to receive and mix a second reactant from at least one of the first, second, and third reactant sources 60, 62, and 64, and supply the mixed second reactant to the second reaction tube 30.

[0050] The first reactant supply source 60 is configured to constantly supply steam to both the first and second mixers 70, 72, the second reactant supply source 62 is configured to selectively supply naphtha to the first and second mixers 70, 72 under the control of a controller (not shown), and the third reactant supply source 64 is configured to selectively supply ethane to the first and second mixers 70, 72 under the control of a controller (not shown). In the example shown in Figure 3, the first reactant supply source 60 supplies steam to both the first and second mixers 70, 72, the second reactant supply source 62 supplies naphtha to both the first and second mixers 70, 72, and the third reactant supply source 64 does not supply ethane to either the first or second mixers 70, 72.

[0051] The first mixer 70 is supplied with steam from the first reactant supply source 60 and naphtha from the second reactant supply source 62, mixes the steam and naphtha, and supplies the mixed steam and naphtha to the first reaction tube 20. The second mixer 72 is also supplied with steam from the first reactant supply source 60 and naphtha from the second reactant supply source 62, mixes the steam and naphtha, and supplies the mixed steam and naphtha to the second reaction tube 30. That is, the mixed steam and naphtha is supplied to the first reaction region 24 and the second reaction region 34.

[0052] The controller controls the first and second power sources 40, 42 to maintain the same temperature in the first and second reaction zones 24, 34. Mixed steam and naphtha are supplied to both the first and second reaction zones 24, 34, and the first and second reaction zones 24, 34 are controlled to the same temperature, causing naphtha steam cracking to occur in both the first and second reaction zones 24, 34.

[0053] Figure 4 shows another example of using an electrically heated reactor according to an embodiment of the present invention. Figure 4 illustrates that the first reaction zone 24 and the second reaction zone 34 are controlled to different temperatures, and naphtha steam cracking occurs in the first reaction zone 24, while ethane steam cracking occurs in the second reaction zone 34.

[0054] As shown in FIG. 4 , the first reactant source 60 supplies steam to both the first and second mixers 70, 72, the second reactant source 62 supplies naphtha to the first mixer 70 but not to the second mixer 72, and the third reactant source 64 supplies ethane to the second mixer 72 but not to the first mixer 70.

[0055] The first mixer 70 is supplied with steam from the first reactant supply source 60 and naphtha from the second reactant supply source 62, mixes the steam and naphtha, and supplies the mixed steam and naphtha to the first reaction tube 20. The second mixer 72 is supplied with steam from the first reactant supply source 60 and ethane from the third reactant supply source 64, mixes the steam and ethane, and supplies the mixed steam and ethane to the second reaction tube 30. That is, the mixed steam and naphtha is supplied to the first reaction region 24, and the mixed steam and ethane is supplied to the second reaction region 34.

[0056] The controller controls the first and second power sources 40 and 42 to maintain different temperatures in the first and second reaction zones 24 and 34. Mixed steam and naphtha are supplied to the first reaction zone 24, and mixed steam and ethane are supplied to the second reaction zone 34. The first and second reaction zones 24 and 34 are controlled to maintain different temperatures, with naphtha steam cracking occurring in the first reaction zone 24 and ethane steam cracking occurring in the second reaction zone 34.

[0057] Although FIGS. 3 and 4 illustrate the use of the electrically heated reactor 10 according to an embodiment of the present invention in at least one of naphtha steam cracking and ethane steam cracking, the use of the electrically heated reactor 10 according to an embodiment of the present invention is not limited to the examples shown in FIGS. 3 and 4. In one example, the electrically heated reactor 10 can be used for reactions in which the types of reactants supplied to the first and second reaction zones 24 and 34 are similar and the reaction temperatures are similar. Examples of reactions that satisfy these conditions include, but are not limited to, methane wet reforming, methane dry reforming, and methane pyrolysis. In another example, the first reaction zone 24 and the second reaction zone 34 can be connected to each other via a connecting passage (not shown) from the outside of the reactor housing 11. The reactants can be preheated in either the first or second reaction zone 24 or 34, and the preheated reactants can be supplied to either the first or second reaction zone 24 or 34, with the main reaction occurring in either the first or second reaction zone 24 or 34.

[0058] Although the preferred embodiments of the present invention have been described above, the present invention is not limited to the above embodiments, and includes all modifications that can be easily made from the embodiments of the present invention by a person having ordinary skill in the art to which the invention pertains and that are recognized as equivalents.

Claims

1. at least one first reaction tube having a first passage formed therein for a reactant to pass therethrough and configured to heat the reactant passing through said first passage; at least one second reaction tube having a second passage formed therein for the passage of a reactant therethrough and configured to heat the reactant passing through said second passage; a first power source configured to provide power to the at least one first reaction tube; and a second power source configured to provide power to the at least one second reaction tube; an electrically heated reactor comprising:

2. 10. The electrically heated reactor of claim 1, wherein the first power source and the second power source are independently controlled.

3. the first passage defines a first reaction zone and the second passage defines a second reaction zone; The electrically heated reactor comprises: a first reactor inlet in communication with the first reaction zone to supply reactants to the first reaction zone; a first reactor outlet in communication with the first reaction zone for discharging reactants from the first reaction zone; a second reactor inlet in communication with the second reaction zone to supply reactants to the second reaction zone; and a second reactor outlet in communication with the second reaction zone for discharging reactants from the second reaction zone; The electrically heated reactor of claim 1 further comprising:

4. 4. The electrically heated reactor of claim 3, wherein the first reaction zone and the second reaction zone are not in communication with each other.

5. a first mixer configured to receive and mix a first type of reactants from a first type of reactant source and deliver the mixed first type of reactants to the first reaction tube; and a second mixer configured to receive and mix a first type of reactants from a first type of reactant source and to deliver the mixed first type of reactants to the second reaction tube; The electrically heated reactor of claim 3 further comprising:

6. the first reaction zone and the second reaction zone are controlled to the same temperature; 6. The electrically heated reactor of claim 5, wherein the first and second reaction zones are supplied with the first reactant from the first and second mixers, respectively, and the same reaction occurs in the first and second reaction zones.

7. a first mixer configured to receive and mix a first type of reactants from a first type of reactant source and deliver the mixed first type of reactants to the first reaction tube; and a second mixer configured to receive and mix a second type of reactants from a second type of reactant source and to deliver the mixed second type of reactants to the second reaction tube; The electrically heated reactor of claim 3 further comprising:

8. The first reaction region and the second reaction region are controlled to different temperatures, 8. The electrically heated reactor of claim 7, wherein a first type of reactant is supplied to the first reaction zone from the first mixer, and a second type of reactant is supplied to the second reaction zone from the second mixer, and different reactions occur simultaneously.

9. the at least one first reaction tube and the at least one second reaction tube are longitudinally disposed within a reactor housing; A partition wall is installed in the reactor housing in the longitudinal direction to physically divide the interior space of the reactor housing into first and second zones; 4. The electrically heated reactor of claim 3, wherein the at least one first reaction tube is disposed in the first zone and the at least one second reaction tube is disposed in the second zone.

10. 2. The electrically heated reactor according to claim 1, further comprising an insulator surrounding at least a portion of the first and second reaction tubes to provide thermal insulation therefrom.

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