System and method for electrical heat exchanger apparatus and reaction technology (e-heart)

Abstract

An electrically heated apparatus for thermal processing, and methods for using same are provided. The electrically heated apparatus can include a housing having at least one inlet and at least one outlet disposed thereon, and two or more stages disposed within the housing, wherein each stage comprises one or more independently controlled internal heating elements (IC-IHEs) and / or one or more independently controlled external heating elements (IC-EHEs). Power provided to each IC-THE and / or TC-EHE can be controlled independently of one another to allow dynamic adjustment of heat or temperature profile along a length of the housing. Power to the IC-IHEs and / or IC-EHEs can derive from ohmic, resistive, induction, microwaves, electric arc, radio frequency, infrared, laser, plasma heating, or a combination thereof, and provide a source of heat.

Description

SYSTEM AND METHOD FOR ELECTRICAL HEAT EXCHANGER APPARATUSAND REACTION TECHNOLOGY (E-HEART)GOVERNMENT LICENSE RIGHTS

[0001] This invention was made with government support under EEC- 1647722 awarded by the National Science Foundation. The government has certain rights in the invention.BACKGROUNDField of the Invention

[0002] The disclosure relates to systems and methods to provide heat to one or more objects, substances, materials, or other matter in electrically heated apparatuses, with a particular emphasis on chemical mixtures or their individual components.Description of the Related Art

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] Heated apparatuses play a vital role across numerous industrial chemical applications. They are particularly important in facilitating endothermic processes, such as cracking, gasification, thermal decomposition, reforming, and dehydrogenation. Heated apparatuses also find application in exothermic processes, for instance, to preheat reactants, maintain temperatures, and enable heat integration, both during startup and operation. Key examples include the synthesis of paraffins, olefins, and methanol, as well as the processing of mixtures containing CO2, CO, and H2 in various proportions.

[0005] Depending on the application, heated apparatuses may be designated with distinctive names. For example, they may be referred to as reactors when employed to drive chemical reactions, heaters when used to elevate the temperature of a process stream, and crackers when utilized to break chemical molecules.

[0006] Over the past century, Flame-heated Tubular Reactors (FTRs) have been the dominant design to drive industrial chemical reactions, especially those at above-ambient temperatures. As illustrated in Figure 1A, key components of an FTR include the reaction tubes (HA), burners (12A), and a firebox (13 A). The feed (101 A) flows through the heated tubes while absorbing energy from the walls and undergoing chemical reactions. The product leaves the system as stream 102 A, while the flue gases exit separately as stream 103 A. Despite their enduring prevalence, FTRs grapple with persistent challenges that undermine theirperformance, primarily stemming from external heating. These limitations encompass constrained heat transfer areas, pronounced thermal gradients, and restricted temperature control. Furthermore, being primarily fueled by the combustion of fossil fuels, FTRs stand as significant contributors to CO2 emissions within the chemical industry.

[0007] Among the primary electrically heated reactor designs currently under consideration by the industry are Impedance Tubular Reactors (ITRs) and External-Resistance Tubular Reactors (ERTRs), illustrated in Figures IB and 1C, and featured in recent patent publications W02023006475 and WO2023016968, respectively. While these designs hold promise for reducing CO2 emissions, they exhibit inherent limitations akin to those observed in FTRs due to their reliance on external heating from the tube walls.

[0008] Designs, like those disclosed in U.S. Patent 11,578,019, aim to address external heating limitations by incorporating electric heating elements within the reactor tubes. This approach reduces radial temperature gradients and augments the heat transfer area. However, methods for achieving precise temperature control for improved productivity are still needed.

[0009] A notable limitation across existing heated reactor designs lies in their inherent inability to efficiently accommodate diverse operational conditions, such as fluctuations in power delivery or flow rate. This challenge becomes more pronounced when integrating intermittent energy sources, such as photovoltaic (PV) or wind, and responding to variations in chain supply and market demands. Present solutions often resort to (i) energy storage, resulting in increased costs, and (ii) tuning the power per unit length, compromising reaction conditions and product integrity.

[0010] Accordingly, there is a continuing need for a simpler and more efficient heat exchanger system and method to provide heat to one or more objects, substances, materials, or other matter.SUMMARY

[0011] It has been surprisingly discovered that a heat exchanger system can regulate electrical demand between a plurality of appliances and / or electrical systems. The present disclosure introduces an enhanced heat exchanger system and method for providing heat to one or more objects, substances, materials, or other matter, particularly at temperatures above ambient. The heat exchanger system and methods for using same offer substantial advantages, including improved flexibility and control to efficiently handle diverse operational conditions, precise temperature control, dynamic regulation of the heated length, and flexibility to accommodate multiple electric heating methods.

[0012] In at least one embodiment, the heat exchanger system includes one or more E- HEART (Electrical Heat Exchanger Apparatus and Reaction Technology) units. The E- HEART units can include two or more stages, arranged in sequence, each stage having Independently Controlled Internal Heating Elements (IC-IHEs) and / or Independently Controlled External Heating Elements (IC-EHEs). The heating elements can utilize various methods for heat generation, such as ohmic, resistive, induction, microwaves, electric arc, radio frequency, infrared, laser, plasma, or any combination thereof, as well as other suitable heating methods.

[0013] In at least one specific embodiment, the heating elements can be subjected to constant or variable energy inputs to promptly respond to fluctuations in power delivery and / or shifts in a process stream to establish a desired temperature profile, enhance yield, deliver heat in a specific zone, reduce undesired side reactions, or other suitable applications. The heating elements can take on one or more orientations within the system, such as co-axial to the flow, parallel to the flow, perpendicular to the flow, or any other suitable orientation. These heating elements can incorporate one or more coatings, catalysts, fins, thermal masses, strips, tapes, or other suitable enhancements to improve their performance.

[0014] In at least specific embodiment, the required power for the E-HEART units can be drawn from one or more sources, including a conventional power grid, renewable or nonrenewable sources, fuel cells, turbines, heat recovery systems, nuclear facilities, Variable Renewable Energy (VRE) sources, portable generators, energy storage units, or other suitable sources.

[0015] The one or more streams can be introduced into the E-HEART unit through one or more inlets. The thermal processing of these streams can be achieved by independently controlling the power supplied to each IC-IHE and / or IC-EHE, allowing for precise adjustments to achieve a desired temperature or heat profile within the unit. Subsequently, the thermally processed substances or matter streams are discharged from the E-HEART unit through one or more outlets.

[0016] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations and are not intended to limit the scope ofthe present disclosure. The accompanying drawings are incorporated into and form a part of the specification to illustrate aspects and examples of the present disclosure. These figures, together with the description, explain the general principles of the disclosure. The figures are only to illustrate examples of how the various aspects of the disclosure are made or used and are not to be considered as limiting the disclosure to only the illustrated and described examples. It is further emphasized that the figures are not necessarily to scale and certain features and views of the figures are exaggerated in scale or schematic for clarity and / or conciseness.

[0018] Figure 1A illustrates a known Flame-heated Tubular Reactor (FTR).

[0019] Figure IB illustrates a known Impedance Tubular Reactor (ITR).

[0020] Figure 1C illustrates a known External-Resistance Tubular Reactor (ERTR).

[0021] Figure 2A illustrates an E-HEART (Electrical Heat Exchanger Apparatus and Reaction Technology) type W, according to one or more embodiments provided herein.

[0022] Figure 2B illustrates an E-HEART type X, according to one or more embodiments provided herein.

[0023] Figure 2C illustrates an E-HEART type Y, according to one or more embodiments provided herein.

[0024] Figure 2D illustrates an E-HEART type Z, according to one or more embodiments provided herein.

[0025] Figure 3A illustrates an E-HEART superstructure with sections of types W, X, Y, Z, or O (Other), according to one or more embodiments provided herein.

[0026] Figure 3B illustrates an E-HEART with multiple consecutive X-type sections, according to one or more embodiments provided herein.

[0027] Figure 4A illustrates an E-HEART with N stages featuring each Independently Controlled Internal Resistive Elements (IC-IREs) and Independently Controlled External Inductive Elements (IC-EIEs), according to one or more embodiments described herein.

[0028] Figure 4B illustrates an E-HEART with N stages featuring each IC-IREs and Independently Controlled External Resistive Elements (IC-EREs), according to one or more embodiments described herein.

[0029] Figure 4C illustrates an E-HEART with N stages featuring each IC-IREs and IC- EREs. Additionally, this design features shared IC-IREs (48C) from stage 1 to N, according to one or more embodiments described herein.

[0030] Figure 4D illustrates an E-HEART with N stages featuring each IC-IREs and IC- EREs. Notably, the IC-IREs present a perpendicular orientation to the flow, according to one or more embodiments described herein.

[0031] Figure 4E illustrates an E-HEART with N stages featuring each IC-IREs and IC- EREs. Notably, the IC-IREs present a perpendicular orientation to the flow. Additionally, the system features shared internal support elements (48E) arranged parallel to the flow from stage 1 to N, according to one or more embodiments described herein.

[0032] Figure 4F illustrates an E-HEART with N stages featuring each IC-IREs and IC- EREs. Notably, the IC-IREs present a parallel orientation to the flow. Furthermore, the system integrates shared IC-IREs (49F) and internal support elements (48F) aligned parallel to the flow, from stage 1 to N, according to one or more embodiments described herein.

[0033] Figure 4G illustrates an E-HEART with N stages featuring each IC-IREs and IC- EREs . Notably, the IC-IREs are oriented parallel to the flow and feature dissipation elements, according to one or more embodiments described herein.

[0034] Figure 4H illustrates an E-HEART with N stages featuring each IC-IREs and IC- EREs. Notably, the dissipation is shared by more than one IC-IRE, according to one or more embodiments described herein.

[0035] Figure 41 illustrates an E-HEART with N stages featuring each IC-IREs and IC-EREs. Notably, the IC-IREs are oriented perpendicular to the flow and feature dissipation elements. Furthermore, the system integrates internal support elements (481) parallel to the flow from stage 1 to N, according to one or more embodiments described herein.

[0036] Figure 5A shows the outlet ethylene composition for different power per unit length values for Example 1 , according to one or more embodiments described herein.

[0037] Figure 5B shows the ethylene composition profile across the reactor length for Example 1 , according to one or more embodiments described herein.

[0038] Figure 5C shows the temperature profile across the reactor length for Example 1, according to one or more embodiments described herein.

[0039] Figure 6A shows the outlet ethylene composition for different power per unit length values for Example 2, according to one or more embodiments described herein.

[0040] Figure 6B shows the outlet ethylene composition for different feed flow rate values for Example 2, according to one or more embodiments described herein.

[0041] Figure 7A shows the heat prole across the E-HEART for Example 3, according to one or more embodiments described herein.

[0042] Figure 7B shows the ethylene composition profile for the E-HEART of Example 3, according to one or more embodiments described herein.

[0043] Figure 7C compares the ethylene composition profile for the E-HEART of Example 3 and a known conventional heated reactor of Example 2, according to one or more embodiments described herein.

[0044] Figure 8A compares the outlet ethylene composition for different flow rate values for E-HEART and the known conventional heated reactor, according to one or more embodiments described herein.

[0045] Figure 8B compares the ethane conversion for different flow rate values for E- HEART and the known conventional heated reactor, according to one or more embodiments described herein.

[0046] Figure 8C compares the energy consumption per unit for different flow rate values for E-HEART and the known conventional heated reactor, according to one or more embodiments described herein.DETAILED DESCRIPTION

[0047] The following description of technology is merely exemplary in nature of the subject matter, manufacture, and use of one or more inventions, and is not intended to limit the scope, application, or uses of any specific invention claimed in this application or in such other applications as may be filed claiming priority to this application, or patents issuing therefrom. Regarding methods disclosed, the order of the steps presented is exemplary in nature, and thus, the order of the steps can be different in various embodiments, including where certain steps can be simultaneously performed.

[0048] The indefinite articles “a” and “an” as used herein indicate “at least one” of the item is present; a plurality of such items may be present, when possible.

[0049] The term “or” is intended to encompass both exclusive and inclusive cases: i.e., “A or B” is intended to be synonymous with “at least one of A and B” unless otherwise expressly specified here.

[0050] Except where otherwise expressly indicated, all numerical quantities in this description are to be understood as modified by the word “about” and all geometric and spatial descriptors are to be understood as modified by the word “substantially” in describing the broadest scope of the technology. “About” when applied to numerical values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If,for some reason, the imprecision provided by “about” and / or “substantially” is not otherwise understood in the art with this ordinary meaning, then “about” and / or “substantially” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters.

[0051] The use of ranges are, unless specified otherwise, inclusive of endpoints and include all distinct values and further divided ranges within the entire range. Thus, for example, a range of “from A to B” or “from about A to about B” is inclusive of A and of B. Disclosure of values and ranges of values for specific parameters (such as amounts, weight percentages, etc.) are not exclusive of other values and ranges of values useful herein. It is envisioned that two or more specific exemplified values for a given parameter may define endpoints for a range of values that may be claimed for the parameter. For example, if Parameter X is exemplified herein to have value A and also exemplified to have value Z, it is envisioned that Parameter X may have a range of values from about A to about Z. Similarly, it is envisioned that disclosure of two or more ranges of values for a parameter (whether such ranges are nested, overlapping, or distinct) subsume all possible combinations of ranges for the value that might be claimed using endpoints of the disclosed ranges. For example, if Parameter X is exemplified herein to have values in the range of 1-10, or 2-9, or 3-8, it is also envisioned that Parameter X may have other ranges of values including 1-9, 1-8, 1-3, 1-2, 2-10, 2-8, 2-3, 3-10, 3-9, and so on.

[0052] Certain terms are used throughout the following description and claims to refer to particular components. As someone skilled in the art will appreciate, various entities can refer to the same component using different names. As such, the naming convention for the elements described here is not intended to limit the scope of the invention unless otherwise explicitly defined here. Further, the naming convention used here is not intended to distinguish among components that differ in name but not in function.

[0053] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent”versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0054] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer, or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the teachings of the example embodiments.

[0055] Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the FIG. is turned over, elements described as “below”, or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

[0056] Additionally, the phraseology and terminology used herein are for the purpose of description and should not be considered limiting. The terms “including”, “comprising”, “having”, “containing”, and “involving”, whether in the written description or the claims, are used in an open-ended fashion and thus should be interpreted to mean “including, but not limited to,” unless otherwise stated. Therefore, such terms are intended to encompass the items listed thereafter, equivalents thereof, and additional items.

[0057] Although the open-ended term “comprising,” as a synonym of non-restrictive terms such as including, containing, or having, is used herein to describe and claim embodiments of the present technology, embodiments may alternatively be described using more limiting terms such as “consisting of” or “consisting essentially of.” Thus, for any given embodiment reciting materials, components, or process steps, the present technology also specifically includes embodiments consisting of, or consisting essentially of, such materials, components, or processsteps excluding additional materials, components or processes (for consisting of) and excluding additional materials, components or processes affecting the significant properties of the embodiment (for consisting essentially of), even though such additional materials, components or processes are not explicitly recited in this application. For example, recitation of a composition or process reciting elements A, B and C specifically envisions embodiments consisting of, and consisting essentially of, A, B and C, excluding an element D that may be recited in the art, even though element D is not explicitly described as being excluded herein.

[0058] The term “apparatus” refers to a set of materials, equipment, devices, or elements designed for a particular purpose or task.

[0059] The term “heated apparatus” refers to any type of apparatus designed to provide heat to one or more objects, substances, materials, or matter. For example, the heated apparatus can be any type of unit operation capable of exchanging heat, including any conventional shell- and-tube heat exchangers, plate heat exchangers, regenerators, dehydrogenators, crackers, and other reactors.

[0060] The term “electrically heated apparatus” refers to any type of heated apparatus that uses electricity as the primary energy source.

[0061] The term “physical process” refers to an action or series of actions that alter the physical properties of one or more objects, substances, materials, or other matter.

[0062] The term “chemical process” refers to an action or series of actions that alter the molecular composition of one or more objects, substances, materials, or other matter, which can be solids, liquids, plasmas, or gases.

[0063] The term “endothermic reaction” refers to any type of chemical process where at a given temperature and pressure, the sum of enthalpies of the products is greater than the sum of enthalpies of the reactants. Such reactions require an external supply of energy to proceed.

[0064] The term “exothermic reaction” refers to any type of chemical process where at a given temperature and pressure, the sum of enthalpies of the products is lower than the sum of enthalpies of the reactants. In this case, heat is generated during the process. However, external heat may be needed in certain cases during startup or operation, for instance, to bring the reactants to a temperature where catalysts have reasonable activity or to maintain the reactor temperature.

[0065] The term “reactor” refers to any type of apparatus used to perform one or more chemical processes.

[0066] The term “endothermic reactor” refers to any type of reactor used to perform one or more endothermic reactions.

[0067] The term “exothermic reactor” refers to any type of reactor used to perform one or more exothermic reactions.

[0068] The term “heaters” refers to any type of apparatus used to elevate the temperature of one or more objects, substances, materials, or other matter.

[0069] The term “cracker” refers to any type of apparatus used to break larger chemical molecules into smaller ones.

[0070] The term “flow path” refers to the route that a feed and / or process stream traverses through an apparatus.

[0071] The term “enclosure” refers to the structure that establishes the boundaries of the flow path in an apparatus.

[0072] The term “tube” refers to a cylindrical structure characterized by a length-to-diameter ratio greater than 2, typically exceeding 5, and more typically exceeding 10.

[0073] The term “tubular reactor” refers to a reactor where tubes are used as enclosures for the flow path.

[0074] The term “reaction tube” refers to any type of tubular enclosure within a tubular reactor.

[0075] The terms “Flame-heated Tubular Reactor” and “FTR” are used interchangeably and refer to a tubular reactor characterized by employing burners to generate heat, primarily fueled by the combustion of fossil fuels.

[0076] The terms “Impedance Tubular Reactor” and “ITR” are used interchangeably and refer to a tubular reactor characterized by the flow of electricity directly through the tube walls to generate heat.

[0077] The terms “External-resistance Tubular Reactor” and “ERTR” are used interchangeably and refer to a tubular reactor distinguished by employing electric resistive elements positioned outside the reaction tubes to generate heat.

[0078] The term “elements” refers to individual components, objects, entities, or devices, each playing a distinct role in the overall functionality of an apparatus.

[0079] The term “heating element” refers to any type of element designed to generate heat.

[0080] The term “internal element” refers to any type of element housed inside an apparatus. When a stream flows inside the apparatus, internal elements establish direct contact with said stream along its flow path.

[0081] The term “external elements” refers to any type of element located outside the interior volume of an apparatus. When a stream flows inside the apparatus, external elements do not directly contact the flowing stream.

[0082] The term “thermally coupled” refers to the condition in which two or more entities, components, devices, substances, elements, feed / process streams, or a combination thereof, are connected or associated in a manner that allows the transfer or exchange of heat between them.

[0083] The term “resistive elements” refers to any type of element that generates heat through the resistance to electrical current.

[0084] The term “inductive elements” refers to any type of element that generates heat through electromagnetic induction. Such heating element(s) (i.e. energy element(s)) can be located external to the reactor and provide heat in a thermally coupled manner.

[0085] The term “dissipation elements” refers to any type of element used to enhance the thermal performance of an apparatus, such as fins, thermal masses, strips, and / or tapes.

[0086] The term “support elements” refers to any type of element that provides mechanical support.

[0087] The term “independently controlled” or “IC” refers to the capability of individualized or separate regulation or management of specific parameters.

[0088] The terms “Independently Controlled Internal Heating Element” and “IC-IHE” are used interchangeably and refer to any type of heating element that is also an internal element and can be independently controlled.

[0089] The terms “Independently Controlled External Heating Element” and “IC-EHE” are used interchangeably and refer to any type of heating element that is also an external element and can be independently controlled.

[0090] The terms “Independently Controlled Internal Resistive Element” and “IC-IRE” are used interchangeably and refer to any type of resistive element that is also an internal element and can be independently controlled.

[0091] The terms “Independently Controlled External Resistive Elements” and “IC-ERE” are used interchangeably and refer to any type of resistive element that is also an external element and can be independently controlled.

[0092] The terms “Independently Controlled External Inductive Elements” and “IC-EIE” are used interchangeably and refer to any type of inductive element that is also an external element and can be independently controlled.

[0093] The term “hydrocarbon” refers to a compound primarily made up of hydrogen and carbon atoms.

[0094] The term “paraffins” refers to saturated hydrocarbons or hydrocarbons that contain only single bonds between carbon atoms.

[0095] The term “olefins” refers to unsaturated hydrocarbons or hydrocarbons that contain at least one carbon-carbon double or triple bond in their chemical structure.

[0096] The term “oligomers” refers to dimers, trimers, tetramers, and / or other molecular structures having less than 26 repeating units.

[0097] The term “natural gas” refers to a mixture of hydrocarbons containing at least 50 mol% methane.

[0098] The term “shale gas” refers to any type of natural gas rich in natural gas liquids (NGLs) obtained from a shale or other tight formation.

[0099] The terms “natural gas liquids” and “NGLs” are used interchangeably and refer to a mixture of hydrocarbons, including ethane, propane, butane, isobutane, and natural gasoline.

[0100] The term “LPG” or Liquefied Petroleum Gas refers to a mixture rich in hydrocarbons such as propane, butane, or a combination of both.

[0101] The term “fuel cell” refers to an electrochemical cell that converts the chemical energy of a fuel, like hydrogen, and an oxidizing agent, like oxygen, into electricity through redox reactions.

[0102] The terms “grid”, “electrical grid”, “electric grid”, or “power grid” are used interchangeably, and all refer to an interconnected network for delivering electricity from power plants to consumers.

[0103] The terms “Variable Renewable Energy” and “VRE” are used interchangeably and refer to sources of electricity generation that fluctuate based on environmental conditions and are not dispatchable. The output from VRE sources like wind and solar is highly variable and uncertain.

[0104] The term “turbine” refers to a device that extracts energy from a feed / process stream and uses it to do mechanical work on a rotating output shaft.

[0105] The term “cracking” refers to any type of endothermic chemical process wherein molecules undergo fragmentation, forming smaller molecules.

[0106] The term “reforming” refers to any type of endothermic chemical process wherein the molecular structure of hydrocarbons is rearranged to produce desired products.

[0107] The term “gasification” refers to any type of endothermic chemical process wherein solid or liquid carbon-containing materials are converted into a gaseous mixture.

[0108] The term “thermal decomposition” refers to any type of endothermic chemical process wherein substances are broken down into simpler compounds by applying heat.

[0109] The term “dehydrogenation” refers to any type of chemical process wherein hydrogen removal occurs, such as the cracking of ethane to produce ethylene.

[0110] The term “tuning the power per unit length” refers to the act of optimizing the power supplied to an apparatus on a lengthy basis.

[0111] The term “heated length” refers to the extent or portion of an apparatus where heat is actively applied.

[0112] The term “feed flow rate reduction” refers to the intentional decrease in the rate at which the stream is supplied to an apparatus, influencing the overall flow dynamics and processes within the system.

[0113] The terms “E-HEART” and “Electrical Heat Exchanger Apparatus and Reaction Technology” are used interchangeably and refer to an electrically heated apparatus designed to provide heat to one or more feed and / or process streams. The E-HEART apparatus can have two or more stages with Independently Controlled Internal Heating Elements (IC-IHEs) and / or Independently Controlled External Heating Elements (IC-EHEs). The E-HEART multi-stage design enables precise control of the temperature and heat profile across the unit. Various heating methods may be utilized, including ohmic, resistive, induction, microwave, electric arc, radio frequency, infrared, laser, plasma heating, or combinations thereof. Electric power can be drawn from any suitable power source such as the grid, renewable / non-renewable generators, fuel cells, turbines, heat recovery systems, nuclear facilities, Variable Renewable Energy (VRE) sources, portable generators, or energy storage units. Key capabilities of E- HEART units include dynamic regulation of the heated length and flexibility to efficiently handle diverse operational conditions.

[0114] The term “type W” refers to any type of E-HEART unit in which the stages do not share any internal or external heating elements.

[0115] The term “type X” refers to any type of E-HEART unit in which the stages share internal heating elements but not external powered or unpowered elements.

[0116] The term “type Y” refers to any type of E-HEART unit in which the stages share external heating elements but not internally powered or unpowered elements.

[0117] The term “type Z” refers to any type of E-HEART unit in which the stages share both internal and external heating elements.

[0118] The term “type O” refers to any type of E-HEART unit having a configuration or architecture that does not fall under the categories of type W, X, Y, or Z. A Type-0 unit can contain unique, hybrid, intermediate, or uncategorized arrangements.

[0119] A more detailed description of the present invention follows. Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on thecontext, all references to the “invention” may, in some cases, refer to certain specific embodiments only. In other cases, references to the “invention” refer to the subject matter recited in one or more of the claims. Each of the inventions is described in greater detail below, including specific embodiments, versions, and examples, but the inventions are not limited to these embodiments, versions, or examples. These are included to enable a person with ordinary skill in the art to make and use the inventions when the information in this disclosure is combined with publicly available information and technology.

[0120] The following detailed description illustrates embodiments of the present disclosure. These embodiments are described in enough detail to enable a person of ordinary skill in the art to practice these embodiments. It should be understood, however, that the embodiments and examples described here are given by way of illustration only and not by way of limitation. The embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of the present teachings. Various substitutions, modifications, additions, and rearrangements are made that remain potential applications of the disclosed processes. Therefore, the following description is not to be taken as limiting the scope of the appended claims. In particular, an element associated with a particular embodiment should not be limited to association with that particular embodiment but should be assumed to be capable of association with any embodiment discussed here.

[0121] As briefly summarized above, the present disclosure describes an Electrical Heat Exchanger Apparatus and Reaction Technology (E-HEART) that can provide heat to one or more feed and / or process streams. It has been surprisingly discovered that the E-HEART units provided herein and methods for using same represent an opportunity to achieve dramatic carbon emissions reductions while boosting production. The E-HEART units provided herein also allow for power availability from renewable energy sources such as photovoltaic (PV) and / or wind. The E-HEART units equipped with internally located heating elements further improve performance by providing better heat transfer where the reaction is needed.

[0122] As used herein, the terms “feed stream” and “process stream” are used interchangeably throughout and refer to any flow of material or energy within a process, acting as either an input entering an operating unit and / or an output leaving an operating unit, including a product stream, a recycle stream that is returned to another stage or step of a process, a bypass stream that skips a certain stage and / or step of a process, a withdraw stream and / or or purge stream that is removed to prevent unwanted accumulation, or an intermediate flow between different steps and / or stages of a process. Any such flow stream can contain one or more liquids, gases, or mixtures thereof. In certain embodiments, the flow stream can be orcan include hydrogen, methane, ethane, propane, butane, natural gas, shale gas, Natural Gas Liquids (NGL), Liquefied Petroleum Gas (LPG), naphtha, coal gas, nitrogen or other inert gas, water, steam, solvents, dilution agents, and / or hydrocarbons. In certain embodiments, the hydrocarbons can be obtained directly or indirectly from a reservoir, wellhead, or pipeline. The one or more feed streams and / or process streams also can be or can include streams associated with refinery processes, separation processes, cryogenic processes, combinations thereof, or other hydrocarbon containing process streams. The one or more feed streams and / or process streams can also be or include one or more recycle streams from unit operations downstream of the E-HEART unit.

[0123] One or more E-HEART units can be used. Each E-HEART unit can include two or more stages, arranged in sequence, each unit having one or more Independently Controlled Internal Heating Elements (IC-IHEs), one or more Independently Controlled External Heating Elements (IC-EHEs), or a combination of both. The E-HEART units enable dynamic adjustment of a temperature profile, heated length, and power input. E-HEART's heating elements can utilize various methods to generate heat, such as ohmic, resistive, induction, microwaves, electric arc, radio frequency, infrared, laser, plasma heating, or combinations thereof. The one or more feed and / or process streams enter through one or more inlets, undergo thermal processing within the stages, and exit via one or more outlets. The E-HEART unit and methods for operating same offer distinct advantages, including enhanced adaptability to diverse operational conditions, increased compatibility with Variable Renewable Energy (VRE) sources, and flexibility to accommodate changing market demands. The E-HEART unit and methods for operating same can draw power from the grid, renewable / non-renewable sources, fuel cells, turbines, heat recovery systems, nuclear facilities, VRE sources, portable generators, energy storage units, and a combination thereof.

[0124] Figure 2A illustrates an E-HEART unit type W, featuring distinct stages without shared internal or external heating elements. The process begins as the feed and / or process stream 201 A enters stage 1 of the unit, progressing sequentially through each stage. Subsequently, leaving the system as product stream 204A. Each stage within this configuration is equipped with independently controlled internal and external heating elements. For instance, 22A and 23 A in stage 1, respectively. The physical boundaries of each stage are delimited by their individual enclosures, such as 21 A, 24A, and 27A for stages 1, i, and N, respectively. Intermediate stages introduce additional versatility, offering the option to incorporate one or more side streams to the system, such as streams 202A and 203A to add feed and withdraw a product from stage i, respectively. The value of N is two or greater i.e., the E-HEART type Wunit can have two or more stages. This design offers flexibility in operation, supporting multiple modes, for instance, in one mode, the feed enters stage 1 and exits entirely through stage N. Alternatively, the feed and / or process streams can enter through stage 1, with a partial exit through stage N, while maintaining system balance with the intermediate outlet stream 203A in stage i. Another operational mode involves the feed and / or process streams entering through the intermediate stream 202A in stage i and exiting through stage N. The choice of operation mode can be contingent on the specific process requirements and can either remain constant or vary over time.

[0125] Figure 2B illustrates an E-HEART type X unit that is distinguished by stages that share internal heating elements while maintaining separate external heating elements. The process initiates with the entry of the feed and / or process stream 20 IB into stage 1, flowing sequentially through each stage. Subsequently, leaving the system as the product stream 202B. Within this configuration, each stage features independently controlled external heating elements, such as 22B, 24B, and 25B for stages 1, i, and, N, respectively. However, the internal heating elements (23B) are shared across stages 1 to N. While not explicitly depicted for simplicity, intermediate-stage side streams may be present to enhance operational flexibility as described for E-HEART type W. The individual stage enclosures are visually represented as a unified body 21B. The value of N is two or greater i.e., the E-HEART type X may consist of two or more stages. This configuration offers a nuanced approach to heat distribution, enabling targeted heat delivery to specific zones through the external heating elements, while maintaining a base load through the shared internal elements 23B.

[0126] Figure 2C illustrates an E-HEART type Y, distinguished by stages that share external heating elements while maintaining separate internal heating elements. The process commences with the entry of the feed and / or process stream 201C into stage 1, progressing sequentially through each stage, and exiting the system as product stream 202C. Within this configuration, each stage incorporates independently controlled internal heating elements, such as 22C, 23C, and 25C for stages 1, i, and, N, respectively. However, the external heating elements 24C are shared across stages 1 to N. Although not explicitly depicted for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are visually represented as a unified body 21C. This configuration can be understood as the negative of type X, allowing targeted heat delivery to specific zones through the internal heating elements, while maintaining a base load through the shared external elements. This configuration facilitates reducing the temperature differences between the inside and outside of the E-HEART, thereby helping to maintain more uniform reactionconditions in the reactor. The value of N is two or greater i.e., the E-HEART type Y may consist of two or more stages.

[0127] Figure 2D illustrates an E-HEART type Z, featuring stages that share both internal and external heating elements. The process initiates with the entry of the feed and / or process stream 20 ID into stage 1, progressing sequentially through each stage. As the stages conclude, the product stream 202D exits the system. Within this configuration, both internal and external heating elements, represented by 22D and 23D, are shared across stages 1 to N. Although not explicitly depicted for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are visually presented as a unified body 21D. The value of N is two or greater i.e., the E-HEART type Z may consist of two or more stages. This configuration enables a collaborative approach to heat distribution, utilizing both internal and external heating elements to maintain a consistent base load across stages. This configuration also simplifies the control system and reduces the number of components involved.

[0128] Figure 3A illustrates an E-HEART superstructure. The feed and / or process stream 301 A enters stage 1 and flows sequentially through each stage, exiting the system as the product stream 302A. The reactor is divided into a number S of sections, and each section can be of type W, X, Y, Z, or O (Other). Type-0 may contain unique, hybrid, intermediate, or uncategorized arrangements. Dotted points are used to indicate the presence of additional intermediate sections between 2 and S-l. Although not explicitly depicted for simplicity, intermediate-stage side streams may be present to enhance operational flexibility.

[0129] Figure 3B illustrates an E-HEART unit with multiple X-type sections. The process initiates with the entry of feed and / or process stream 30 IB into Section A, with stages 1 to i, featuring IC-IHEs 3 IB, and IC-EHEs 32B and 33B. As the stages progress, the reactants enter Section H, with stages] to k, featuring IC-IHEs 34B, and IC-EHEs 35B and 36B. Before exiting the unit, the reactants pass through Section Z, with stages M to N, featuring IC-IHEs 37B, and IC-EHEs 38B and 39B. The product exists as stream 302B. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. This embodiment serves as an illustrative example of the designs generated by the superstructure of Figure 3A.

[0130] Figure 4 A illustrates an E-HEART unit with N stages, each having Independently Controlled Internal Resistive Elements (IC-IREs) and Independently Controlled External Inductive Elements (IC-EIEs). For example, stage 1 incorporates IC-IREs 42 A and IC-EIEs 43 A, while stage i employs IC-IREs 44A and IC-EIEs 44A, and stage N uses IC-IREs 46A andIC-EIEs 47A. The process initiates with the entry of feed and / or process stream 401 A into stage 1, flowing sequentially through each stage, exiting the system as the product stream 402A. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are depicted as a single body 41 A. The internal resistive elements provide direct heating inside the E-HEART enclosure for precise temperature control. The external inductive coils allow non-contact heating from outside to supplement the internal heat as needed. This multi-heating approach enhances thermal transfer and flexibility. This Figure serves as an example of the use of more than one method for heat generation in a single E-HEART. Numerous combinations and permutations can be created using other methods, such as ohmic, resistive, induction, microwaves, electric arc, radio frequency, infrared, laser, plasma, or other suitable heating methods. However, for simplicity, only this combination is explicitly illustrated.

[0131] Figure 4B illustrates an E-HEART unit with N stages, each having IC-IREs and Independently Controlled External Resistive Elements (IC-EREs). For example, stage 1 incorporates IC-IREs 42B and IC-EREs 43B, while stage i employs IC-IREs 44B and IC-EREs 45B, and stage N uses IC-IREs 46B and IC-EREs 47B. The process initiates with the entry of feed and / or process stream 401B into stage 1, flowing sequentially through each stage, exiting the system as the product stream 402B. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are depicted as a single body 41B. The external resistive coils provide bulk heating, while the internal coils fine-tune the temperature profile. This configuration is well-suited for high- temperature operations where inductive heating efficacy may decrease.

[0132] Figure 4C illustrates an E-HEART unit with N stages, each having IC-IREs and IC- EREs. For example, stage 1 incorporates IC-IREs 42C and IC-EREs 43C, while stage i employs IC-IREs 44C and IC-EREs 45C, and stage N uses IC-IREs 46C and IC-EREs 47C. The process initiates with the entry of feed and / or process stream 401 C into stage 1, flowing sequentially through each stage, exiting the system as the product stream 402C. Notably, this design incorporates shared IC-IREs, 48C, between stages 1 to N for bulk heating. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are depicted as a single body 41C. This configuration balances efficiency through shared heating elements with flexibility from independent heating elements.

[0133] Figure 4D illustrates an E-HEART unit with N stages, each having IC-IREs and IC- EREs. For example, stage 1 incorporates IC-IREs 42D and IC-EREs 43D, while stage iemploys IC-IREs 44D and IC-EREs 45D, and stage N uses IC-IREs 46D and IC-EREs 47D. The process initiates with the entry of feed and / or process stream 40 ID into stage 1, flowing sequentially through each stage, exiting the system as the product stream 402D. In general, the heating elements may be oriented in any direction within or outside the reactor. However, in this Figure, the IC-IREs are oriented perpendicular to the flow. This Figure is a variation of Figure 4B and serves as an example of the possibility of creating new configurations by changing the orientation of heating elements within an E-HEART. Optimizing the heating element orientations can enhance internal mixing, heat transfer, and overall performance. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are depicted as a single body 41D.

[0134] Figure 4E shows an E-HEART unit with N stages, each having IC-IREs and IC-EREs. For example, stage 1 incorporates IC-IREs 42E and IC-EREs 43E, while stage i employs IC- IREs 44E and IC-EREs 45E, and stage N uses IC-IREs 46E and IC-EREs 47E. The process initiates with the entry of feed and / or process stream 40 IE into stage 1, flowing sequentially through each stage, exiting the system as the product stream 402E. Notably, this design incorporates shared internal support elements 48E between stages 1 to N. This Figure is a variation of Figure 4D and serves as an example of the use of internal support elements within an E-HEART. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are depicted as a single body 4 IE. The shared internal support can provide structural stability for the internal heating elements. This enables large resistive elements for uniform heating while maintaining mechanical integrity.

[0135] Figure 4F shows an E-HEART unit with N stages, each having IC-IREs and IC-EREs. For example, stage 1 incorporates IC-IREs 42F and IC-EREs 43F, while stage i employs IC- IREs 44F and IC-EREs 45F, and stage N uses IC-IREs 46F and IC-EREs 47F. The process initiates with the entry of feed and / or process stream 40 IF into stage 1, flowing sequentially through each stage, exiting the system as the product stream 402F. Notably, this design incorporates shared internal support elements 48F and IC-IRE 49F between stages 1 to N. This Figure is a variation of Figure 4C and serves as another example of the use of internal support elements within an E-HEART. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are depicted as a single body 4 IF.

[0136] Figure 4G shows an E-HEART unit with N stages, each featuring IC-IREs and IC- EREs. For example, stage 1 incorporates IC-IREs 42G and IC-EREs 43G, while stage iemploys IC-IREs 44G and IC-EREs 45G, and stage N uses IC-IREs 46G and IC-EREs 47G. The process initiates with the entry of feed and / or process stream 401G into stage 1, flowing sequentially through each stage, exiting the system as the product stream 402G. Notably, in this design, the internal resistive elements include dissipation elements. This Figure is a variation of Figure 4B and serves as an example of the use of fins, thermal masses, strips, and / or tapes to enhance the E-HEAR performance. These elements create additional heat transfer areas and allow more homogeneous heat transfer. Moreover, the additional area may be used to incorporate coatings and catalysts. Although not shown for simplicity, intermediatestage side streams may be present to enhance operational flexibility. The stage enclosures are depicted as a single-body 41G. The dissipation in the heating elements can help transfer heat and generate turbulence.

[0137] Figure 4H illustrates an E-HEART unit with N stages, each featuring IC-IREs and IC-EREs. For example, stage 1 incorporates IC-IREs 42H and IC-EREs 43H, while stage i employs IC-IREs 44H and IC-EREs 45H, and stage N uses IC-IREs 46H and IC-EREs 47H. The process initiates with the entry of feed and / or process stream 401H into stage 1, flowing sequentially through each stage, exiting the system as the product stream 402G. This Figure is a variation of Figure 4G and serves as another example of the use of dissipation elements to enhance E-HEAR performance. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The stage enclosures are shown as a single body 41H. Internal resistive elements with dissipation 42G in Figure 4G and 42H in Figure 4H are different arrangements for electrical heating and they could be drawn from other known configurations, such as the ones disclosed in US patent 11,578,019 B2.

[0138] Figure 41 shows an E-HEART unit with N stages, each having IC-IREs and IC-EREs. For example, stage 1 incorporates IC-IREs 421 and IC-EREs 431, while stage i employs IC- IREs 441 and IC-EREs 451, and stage N uses IC-IREs 461 and IC-EREs 471. The process initiates with the entry of feed and / or process stream 4011 into stage 1, flowing sequentially through each stage, exiting the system as the product stream 4021. Notably, this design has shared internal support elements 481 between stages 1 to N. This Figure is a variation of Figures 4E and 4G and serves as an example of the use of both supporting elements and dissipation elements. Although not shown for simplicity, intermediate-stage side streams may be present to enhance operational flexibility. The individual stage enclosures are depicted as a single body 411. The IC-IREs with dissipation may feature any orientation within the reactor.

[0139] In at least one embodiment, the E-HEART unit, alongside the heating elements, can incorporate one or more supplementary elements serving one or more functions including,providing mechanical support, influencing flow mixing, creating an active surface, offering thermal insulation, adding aesthetic value, facilitating partial or complete separation of one or more components, or any other suitable function. The E-HEART unit can also include one or more seamless tubes, spiral-welded tubes, flat or bent plates, inlet / outlet ports, a combination thereof, or any other suitable components joined together by appropriate means.

[0140] It should be noted that the IC-IREs discussed herein can be any suitable arrangement of one or more electrically heated resistances or elements. Some examples can be found in U.S. Patent No. 1 1 ,578,019 B2. Similarly, IC-EREs may employ direct current flow through the unit enclosure as described in patent publications W02023006475A1 and WO2023016968A1. In such cases, the unit enclosure of each stage, as illustrated by 21A, 24A, and 27A in Figure 2A, should be independent and will act as IC-EHEs. Other examples are shown in Figures 4A to 41, depicting other electrically heated reactors where power input to various sections of the unit can be independently controlled to enhance the unit performance as feed flowrate or power is turned down over a range. This allows for power availability from renewable energy sources such as photovoltaic (PV) and / or wind. The use of internally located heating elements that further improve performance by providing better heat transfer where the reaction is needed.

[0141] Still referring to Figures 2A-4I, the number of stages i refers to an integer “i” that can range of from 1 to 100, such as 1 to 50, or 1 to 30, or 1 to 15; and N also refers to an integer that can range of from of from 1 to 100, such as 1 to 50, or 1 to 30, or 1 to 15. It should be further appreciated that one or more thermocouples (not shown) can be used at various locations (both radially and longitudinally) along and / or within the reactor to measure, monitor and / or control the temperature profile along the length of the reactor. Any suitable type of thermocouple can be used.

[0142] In at least one embodiment, any of the E-HEART unit configurations provided herein can be employed in above-ambient endothermic processes such as cracking, gasification, thermal decomposition, reforming, and / or dehydrogenation. Additionally, any of the the E- HEART unit configurations can be employed for the startup or operation of exothermic processes such as the synthesis of paraffins, olefins, and methanol, and / or the processing of mixtures containing CO2, CO, and H2 in various proportions. Other suitable applications include hydrocarbon upgrading with potential conversion into oligomers, preheating reactants, enabling temperatures, enabling heat integration, or other suitable applications. Above-ambient temperatures can range from about 50°C to 1400°C, preferably 100°C to 900°C, and more preferably 250°C to 900°C.

[0143] For example, any of the forgoing E-HEART unit configurations can be used to convert one or more paraffins (saturated hydrocarbons) within a feed stream to one or more olefins (unsaturated hydrocarbons) which can be further converted to one or more oligomers. The feed stream can be treated to remove acid gas and / or water within upstream processing units to provide a “dry shale gas” or “sweet and dry shale gas” stream. For simplicity and ease of description, the terms “shale gas” or “natural gas” or “dry shale gas” and “sweet and dry shale gas” all refer to any gas mixture containing at least 50 mol% methane and at least 5 mol% NGL.

[0144] The upgraded stream can then be processed within a higher temperature processing unit. The higher temperature processing unit can be one or more thermal or catalyst crackers, steam methane reformers, or other dehydrogenation units for converting one or more paraffins to one or more olefins. Suitable crackers are described in US patents US5181990A and US20090252660A1. The higher temperature processing unit can be a single processing unit or multiple processing units arranged in parallel or series. The higher temperature processing unit can operate at any temperature between about 55O°C and 950°C, and at any pressure between about 1 bar and 30 bars. For example, the reaction product stream exiting the higher temperature processing unit can have a temperature above 200°C, or above 500°C, or above 700°C and a pressure above 2 bars, or above 5 bars. The operating temperature and pressure can change to meet any design specifications.

[0145] The reaction product stream exiting the higher temperature processing unit can contain methane and one or more C2+ hydrocarbons. The reaction product stream can then be rapidly cooled or quenched and then be introduced to one or more oligomerization reactors or systems where the olefins within the stream can be converted to one or more oligomers. The oligomerization process can operate at a relatively lower temperature (200°C to 600°C) and medium pressure ( 1 bar to 50 bar). The typical operating pressure ranges from about 5 bar to about 30 bar and the operating temperature typically ranges from about 100°C to about 300°C. The oligomer product stream can contain a mixture of C4-C26 hydrocarbons with a majority of the higher molecular weight hydrocarbons being greater than C6, and preferably C10-C18, or even more carbon atoms.

[0146] By “oligomer(s)”, it is meant dimers, trimers, tetramers, and other molecular complexes having less than 26 repeating units. Additionally, olefin products with carbon numbers, which are not multiples of the starting reactant are also produced. Oligomers provided herein are typically gases or liquids at ambient temperature, and can include low melting solids, including waxes, at ambient temperature. In some embodiments, the oligomers providedherein, which are suitable for production of gasoline and diesel fuels, can have an atomic weight or molecular weight of less than 1000 AMU (Da), such as about 500 or less, 400 or less, 300 or less, or 200 or less. The molecular weight of the oligomer, for example, can range from a low of about 50, 250 or 350 to a high of about 500, or 1,000 AMU (Da).PROPHETIC EXAMPLES

[0147] The foregoing discussion can be further described with reference to the following prophetic examples. Although the following examples are directed to specific embodiments, they are not to be viewed as limiting in any specific respect.

[0148] The following prophetic examples compare the cracking process of a feed stream in a conventional heated reactor (similar to those depicted in Figures 1A to 1C) versus an E- HEART (similar to those depicted in Figures 2A to 41). The goal of these examples is to illustrate the superior performance of the E-HEART units to variable process conditions, as it may be one of the most important applications for E-HEART units.

[0149] To ensure a fair and meaningful comparison, all cases assigned the same feed, reactor size, and energy input. Ideal plug-flow and isobaric conditions are used to eliminate dispersion and pressure-drop effects. Material and transport contributions are taken to be negligible through ideal heat transfer and constant thermal conductivity assumptions. The absence of diluent usage eliminates dilution influences. These assumptions isolate the configuration effects and ensure the difference in performance solely comes from the difference in the reactor configuration.

[0150] In the examples that follow, the reactor dimensions are summarized in Table 1 and the feed conditions are summarized in Table 2.

[0151] Table 1: Reactor dimensions.

[0152] Table 2: Feed stream properties.Example 1 ( Conventional Heated Reactors - Power Input Optimization )

[0153] As the feed flows through the reactor, such as steams 101A in Figure 1A, 101B in IB, or 101C in 1C, thermal energy from the hot tube walls drives cracking reactions, producing primarily ethylene. The amount of product obtained depends on the energy input. For instance, at 5 kW / m, outlet ethylene composition reaches -20%, while at 8 kW / m, -35%. However, at 15 kW / m it decreases to -0%, indicating the presence of an intermediate preference. Figure 5A graphically presents the correlation between power input and outlet ethylene mass fraction, indicating an optimal energy input of 10 kW / m.

[0154] Figures 5B and 5C illustrate the temperature and ethylene composition profiles along the reactor length at 10 kW / m input, which for the given dimension of the reactor and feed flowrate, gives the highest concentration of ethylene in the outlet stream. These figures reveal ethylene composition does not immediately rise upon entering the reactor, since an initial preheating zone is required to reach a temperature significant for cracking reactions. In the initial 10 m, the temperature rapidly increases, going from 500°C to about 700°C as heat primarily goes into heating the feed. At about 10 m, ethylene composition begins increasing steadily, while the temperature rise declines as more energy is consumed by the endothermic cracking reaction. In this context, the chemical reaction acts as a thermal sink, slowing the temperature increase. Near the reactor outlet, the temperature slope rises again as fewer reactants remain to absorb the heat. Ethylene composition peaks at about 40% at the 50-meter mark, leaving the system at about 88O°C.Example 2 (Conventional Heated Reactors - Limitations Responding to Variable Process Conditions)

[0155] This example studies the case when lower production is needed or insufficient power is available, reducing the feed flow rate becomes necessary. This situation can arise due to various factors, such as integrating intermittent energy sources, responding to variations in supply chain, or adapting to changes in market demand or wellhead production. In thesescenarios, conventional heated reactors resort to lowering the power per unit length, a compromise that can negatively impact reaction conditions and product integrity.

[0156] For instance, if the feed flow was halved while using the dimensions of the reactor of Table 1, a reasonable initial estimate might be to also halve the power per unit length. Thereby, going from a feed flow rate of 120 g / s and a power per unit length of 10 kW / m to a feed flow rate of 60 g / s and a power per unit length of 5 kW / m. However, at 60 g / s and 5 kW / m, the outlet ethylene composition is only about 31%, representing a decrease in performance by a factor of 0.78 compared to the about 40% outlet ethylene composition obtained at 120 g / s and 10 kW / m in Example 1. Introducing more energy further exacerbates the loss. For example, at 6 kW / m the outlet ethylene composition drops sharply to about 6%.

[0157] Figure 6A demonstrates that even if the power input is readjusted to maximize the concentration of ethylene in the output stream, the outlet ethylene composition reaches to about 35% at a power input of 4.5 kW / m, failing to reach 40%. This decline in performance is not limited to a 50% reduction in feed flow. In fact, as illustrated in Figure 6B, unless the reactor operates at the design conditions, it no longer achieves the 40% outlet ethylene composition.Example 3 (The benefits of E-HEART)

[0158] This example evaluates the E-HEART units illustrated in Figures 2A to 41. It was unexpectedly discovered that the E-HEART units can efficiently handle diverse operational conditions by independently controlling their heating elements. In this study, the power per unit length, 10 kW / m, is the same as in Example 1 , and the heating length is half that of Example 1. If the feed flow is halved, as in Example 2, the E-HEART units can turn down half of the heating stages, establishing a heat profile like the one illustrated in Figure 7A. This generates an outlet ethylene mass fraction of -40%, the same value obtained before in Example 1, unlike the -35% obtained with the known conventional heated reactor found in Example 2, as illustrated in Figure 7B. Note that while the overall length of the reactor remains the same as in Example 1 (Table 1), the heating elements are half in length and located near the exit end of the reactor tube. For comparison, Figure 7C offers a simultaneous view of the ethylene composition profile for the known conventional heated reactor found in Example 2 and E- HEART.

[0159] Based on these results, it is believed that a two-stage E-HEART of the type W (N=2), as illustrated in Figure 2A, is preferred where most of the electrical heating is provided in the second-stage IC-IHEs and / or IC-EHEs. If needed, however, a small amount of power could be provided in stage 1. If a type X E-HEART, as illustrated in Figure 2B, with two stages is used,then very little to no power will be supplied in the IC-IHEs and most of the power will be directed to the second stage IC-EHEs. Similarly, for a two-stage type Y E-HEART, as illustrated in Figure 2C, little to no power will be applied in the IC-EHEs, and most of the power will be directed to the second-stage IC-IHEs. A single type Z E-HEART would not allow this flexibility, since all the IC-IHEs and IC-EHEs are shared between stages. However, as illustrated in the superstructure of Figure 3A, a system with two sections (S=2) of type Z is also possible. In such a case, little to no power will be applied in the first section, and most of the power will be directed to the second section. Basically, power at turndown is provided in the section immediately preceding the E-HEART exhaust. However, if the product stream can be withdrawn between stages, as illustrated by stream 203A in Figure 2A, then most if not all power can be applied to the first stage / section, and the product is withdrawn from an intermediate stream between stages / sections. Essentially, these configurations provide flexibility to apply power where needed to maximize yield.Example 4 (Generalization of the Results)

[0160] Example 4 builds upon the insights gained from Example 3 by extending the analysis across the full spectrum of flow rate reductions. The goal of this example is to demonstrate the widespread applicability of the advantages offered by E-HEART units. Figures 8 A to 8C compare three critical parameters for varying feed flow rates when employing conventional heated reactors and the E-HEART units. Figure 8A demonstrates that E-HEART consistently yields a higher or equal outlet ethylene composition compared to conventional heated reactors across all feed flow rates. Figure 8B illustrates how E-HEART units consistently achieve a higher or equal ethylene conversion than conventional heated reactors across all cases. Figure 8C shows that E-HEART units consistently consume less or equal total energy than conventional heated reactors per unit mass of ethylene product.

[0161] The foregoing examples underscore the versatility and efficiency of the E-HEART units, showing that the E-HEART units can provide effective solutions to changes in feed conditions, power delivery variations, and temperature control. For example, the foregoing examples show that the E-HEART units can significantly improve the reaction profile and residence time during turndown of feed / power. The foregoing examples further show that the E-HEART units allow independent control of the reactor length where electrical heating is applied (heated length) and also the amount of electrical power that is applied. The use of multiple electrically heated sections that are independently controlled provide this much- needed flexibility. Thus, if a three-section E-HEART is chosen, it could use the three heated sections for 100% of the design feed flow rate, two of the three sections when the feed is turneddown to 2 / 3rd of the design flow, and only one of the sections when the feed is turned down to l / 3rd of the design flow. Conversely, when not enough electric power is readily available, a three-section E- HEART could apply power to the three sections when 100% of the design power is available, two of the three sections when 2 / 3rd of the design power is available, and only one of the sections when the l / 3rd of the design power is available. Note that "apply power” to a section means the majority of power is directed to that section, while a minor quantity (i.e. <30%, <20%, <10, <5%, or <1%) may still be applied to other sections, while maintaining the ability to obtain a desired temperature profile, preheat reactants, and / or overcome heat losses to the environment. Increasing the number of stages and / or sections further enables finer modulation of the heated length and power input in response to varying process conditions.

[0162] The present invention can further include any one or more of the numbered embodiments below:

[0163] Embodiment 1 : An electrically heated apparatus for thermal processing, comprising a housing having at least one inlet and at least one outlet disposed thereon; two or more stages disposed within the housing, each stage comprising one or more independently controlled internal heating elements (IC-IHEs) and / or one or more independently controlled external heating elements (IC-EHEs), wherein power provided to each IC-IHE and / or IC-EHE is controlled independently of one another to allow dynamic adjustment of heat or temperature profile along a length of the housing, and wherein the IC-IHEs and / or IC-EHEs utilize ohmic, resistive, induction, microwaves, electric arc, radio frequency, infrared, laser, plasma heating, or a combination thereof, as a source of the heat.

[0164] Embodiment 2: The electrically heated apparatus according to embodiment 1, wherein each IC-IHE is in direct contact with a process stream flowing through the housing.

[0165] Embodiment 3: The electrically heated apparatus according to embodiments 1 and / or2, wherein the IC-EHEs are located external to a process stream flowing through the housing and thermally coupled to the process stream.

[0166] Embodiment 4: The electrically heated apparatus according to any embodiment 1 to3, wherein the IC-IHEs and / or IC-EHEs are organized into at least two stages, and the IC-IHEs and / or IC-EHEs are not shared between stages.

[0167] Embodiment 5 : The electrically heated apparatus according to any embodiment 1 to4, further comprising one or more temperature sensors along the length of the housing to provide temperature feedback for control of the unit.

[0168] Embodiment 6: The electrically heated apparatus according to any embodiment 1 to5, wherein a process stream introduced to the housing comprises one or more reactants for above-ambient endothermic processes selected from the group consisting of cracking, gasification, thermal decomposition, reforming, and dehydrogenation.

[0169] Embodiment 7 : The electrically heated apparatus according to any embodiment 1 to6, wherein a process stream introduced to the housing comprises one or more reactants for above-ambient exothermic processes synthesizing paraffins, olefins, methanol, and / or the processing of mixtures containing CO2, CO, and H2 in various proportions.

[0170] Embodiment 8: The electrically heated apparatus according to any embodiment 1 to7, wherein the power is drawn from one or more power sources comprising the grid, renewable or non-renewable energy sources, fuel cells, turbines, heat recovery systems, nuclear facilities, Variable Renewable Energy (VRE) sources, portable generators, energy storage units, or combinations thereof.

[0171] Embodiment 9: The electrically heated apparatus according to any embodiment 1 to8, wherein a process stream introduced to the housing comprise hydrogen, methane, ethane, propane, butane, natural gas, shale gas, Natural Gas Liquids (NGL), Liquefied Petroleum Gas (LPG), naphtha, coal gas, inert gases, water, dilution agents, hydrocarbons obtained from a reservoir, wellhead, or pipeline, or combinations thereof.

[0172] Embodiment 10: The electrically heated apparatus according to any embodiment 1 to9, wherein a process stream introduced to the housing comprises one or more streams from refinery processes, separation processes, cryogenic processes, recycle streams from downstream E-HEART units, streams for hydrocarbon upgrading with potential conversion into oligomers, preheating streams, and / or streams for heat integration.

[0173] Embodiment 11 : The electrically heated apparatus according to any embodiment 1 to10, wherein the one or more IC-IHEs and / or IC-EHEs include one or more dissipation elements selected from the group consisting of fins, thermal masses, strips, tapes, and / or coatings, or catalysts.

[0174] Embodiment 12: The electrically heated apparatus according to any embodiment 1 to11 , wherein each stage further comprises additional elements for mechanical support, flow mixing, active surface creation, thermal insulation, aesthetics, separation, catalyst, or a combination thereof.

[0175] Embodiment 13: The electrically heated apparatus according to any embodiment 1 to12, wherein each stage consists of one or more seamless tubes, spiral-welded tubes, flat plates, bent plates, or a combination thereof.

[0176] Embodiment 14: A method for operating an electrically heated apparatus, comprising: introducing a process stream into one or more inlets disposed about an electrically heated apparatus, the apparatus comprising a housing that contains two or more stages, each stage comprising one or more independently controlled internal heating elements (IC-IHEs) and / or one or more independently controlled external heating elements (IC-EHEs), independently controlling electrical power to each IC-IHEs and / or IC-EHEs of the electrically heated apparatus to obtain a desired operating temperature or heat profile along a length of the housing to provide a thermally processed stream, wherein the IC-IHEs and / or IC-EHEs utilize ohmic, resistive, induction, microwaves, electric arc, radio frequency, infrared, laser, plasma heating, or a combination thereof, as a source of heat; and discharging the thermally processed stream via one or more outlets disposed about the housing of the electrically heated apparatus.

[0177] Embodiment 15: The method according to embodiment 14, further comprising responding to changes in flowrate, available power, stream composition, stream temperature, product demand, or product specifications by adjusting one or more parameters selected from the group consisting of the electrical power supplied to the IC-IHEs and / or IC-EHEs, the process stream flowrate to the inlets, the heated length of the electrically heated apparatus, and the ports for outlet of the process streams.

[0178] Embodiment 16: The method according to embodiments 14 and / or 15, wherein the operating temperature ranges from around 50 °C to 1400 °C.

[0179] Embodiment 17: The method according to embodiments 14 and / or 15, wherein the operating temperature ranges from around 100°C to 900°C.

[0180] Embodiment 18: The method according to any embodiments 14 to 17, wherein the process stream comprises a mixture of natural gas liquids.

[0181] It has been unexpectedly and surprisingly discovered that E-HEART units are versatile, allowing the appropriate choice of sections that need to be heated for a given flow rate or power availability. The E-HEART units provided herein essentially allow the flexibility and / or adjustment of a preferred or desirable heat / temperature profile across a reactor as flowrates and available power change in time.

[0182] Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. Ranges, including the combination of any two values, e.g., the combination of any lower value with any upper value, the combination of any two lower values, and / or the combination of any two upper values, are contemplated unless otherwise indicated. Certain lower limits, upper limits, and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, meaning thevalues take into account experimental error, machine tolerances, and other variations a person with ordinary skill in the art would expect.

[0183] The foregoing has also outlined features of several embodiments so that those skilled in the art can better understand the present disclosure. Those skilled in the art should appreciate that they can readily use the present disclosure as a basis for designing or modifying other methods or devices for carrying out the same purposes and / or achieving the same advantages of the embodiments disclosed herein. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that they can make various changes, substitutions, and alterations herein without departing from the spirit and scope of the present disclosure, and the scope thereof is determined by the claims that follow.

[0184] Various terms have been defined above. To the extent that a term used in a claim is not defined above, it should be given the broadest definition that those in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated to the extent that such disclosure is not inconsistent with this application and covers all jurisdictions in which such incorporation is permitted.

[0185] Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms, and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Equivalent changes, modifications and variations of some embodiments, materials, compositions, and methods can be made within the scope of the present technology, with substantially similar results, without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. An electrically heated apparatus for thermal processing, comprising: a housing having at least one inlet and at least one outlet disposed thereon; two or more stages disposed within the housing, each stage comprising one or more independently controlled internal heating elements (IC-IHEs) and / or one or more independently controlled external heating elements (TC-EHEs), wherein power provided to each IC-IHE and / or IC-EHE is controlled independently of one another to allow dynamic adjustment of heat or temperature profile along a length of the housing, and wherein the IC-IHEs and / or IC-EHEs utilize ohmic, resistive, induction, microwaves, electric arc, radio frequency, infrared, laser, plasma heating, or a combination thereof, as a source of the heat.

2. The electrically heated apparatus of claim 1 , wherein each IC-IHE is in direct contact with a process stream flowing through the housing.

3. The electrically heated apparatus of claim 1, wherein the IC-EHEs are located external to a process stream flowing through the housing and thermally coupled to the process stream.

4. The electrically heated apparatus of claim 1, wherein the IC-IHEs and / or IC-EHEs are organized into at least two stages, and the IC-IHEs and / or IC-EHEs are not shared between stages.

5. The electrically heated apparatus of claim 1, further comprising one or more temperature sensors along the length of the housing to provide temperature feedback for control of the unit.

6. The electrically heated apparatus of claim 1 , wherein a process stream introduced to the housing comprises one or more reactants for above-ambient endothermic processes selected from the group consisting of cracking, gasification, thermal decomposition, reforming, and dehydrogenation.

7. The electrically heated apparatus of claim 1, wherein a process stream introduced to the housing comprises one or more reactants for above-ambient exothermic processes synthesizing paraffins, olefins, methanol, and / or the processing of mixtures containing CO2, CO, and H2 in various proportions.

8. The electrically heated apparatus of claim 1, wherein the power is drawn from one or more power sources comprising the grid, renewable or non-renewable energy sources, fuel cells, turbines, heat recovery systems, nuclear facilities, Variable Renewable Energy (VRE) sources, portable generators, energy storage units, or combinations thereof.

9. The electrically heated apparatus of claim 1, wherein a process stream introduced to the housing comprise hydrogen, methane, ethane, propane, butane, natural gas, shale gas, Natural Gas Liquids (NGL), Liquefied Petroleum Gas (LPG), naphtha, coal gas, inert gases, water, dilution agents, hydrocarbons obtained from a reservoir, wellhead, or pipeline, or combinations thereof.

10. The electrically heated apparatus of claim 1 , wherein a process stream introduced to the housing comprises one or more streams from refinery processes, separation processes, cryogenic processes, recycle streams from downstream E-HEART units, streams for hydrocarbon upgrading with potential conversion into oligomers, preheating streams, and / or streams for heat integration.

11. The electrically heated apparatus of claim 1 , wherein the one or more IC-IHEs and / or IC-EHEs include one or more dissipation elements selected from the group consisting of fins, thermal masses, strips, tapes, and / or coatings, or catalysts.

12. The electrically heated apparatus of claim 1, wherein each stage further comprises additional elements for mechanical support, flow mixing, active surface creation, thermal insulation, aesthetics, separation, catalyst, or a combination thereof.

13. The electrically heated apparatus of claim 1, wherein each stage consists of one or more seamless tubes, spiral-welded tubes, flat plates, bent plates, or a combination thereof.

14. A method for operating an electrically heated apparatus, comprising: introducing a process stream into one or more inlets disposed about an electrically heated apparatus, the apparatus comprising a housing that contains two or more stages, each stage comprising one or more independently controlled internal heating elements (IC-IHEs) and / or one or more independently controlled external heating elements (IC-EHEs), independently controlling electrical power to each IC-IHEs and / or IC-EHEs of the electrically heated apparatus to obtain a desired operating temperature or heat profile along a length of the housing to provide a thermally processed stream, wherein the IC-IHEs and / or IC- EHEs utilize ohmic, resistive, induction, microwaves, electric arc, radio frequency, infrared, laser, plasma heating, or a combination thereof, as a source of heat; and discharging the thermally processed stream via one or more outlets disposed about the housing of the electrically heated apparatus.

15. The method of claim 14, further comprising responding to changes in flowrate, available power, stream composition, stream temperature, product demand, or product specifications by adjusting one or more parameters selected from the group consisting of the electrical power supplied to the IC-IHEs and / or IC-EHEs, the process stream flowrate to the inlets, the heated length of the electrically heated apparatus, and the ports for outlet of the process streams.

16. The method of claim 14, wherein the operating temperature ranges from around 50°C to 1400°C.

17. The method of claim 15, wherein the operating temperature ranges from around 100°C to 900°C.

18. The method of claim 14, wherein the process stream comprises a mixture of natural gas liquids.

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