Electric Feedthrough Assembly for Heated Ammonia Pressure Vessels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric feedthroughs fail in high temperature, high pressure, and corrosive environments, such as those found in ammonia cracking systems, due to susceptibility to thermal stress, mechanical stress, and chemical attack from gases like heated ammonia, leading to damage and failure.
Innovation Solution
The electric feedthrough assembly employs a pass-thru stud with nickel alloy washers and ceramic washers, surrounded by an insulating sleeve, and a body with internal threading, designed to couple with pressure vessel fittings, using materials like Inconel and silver for enhanced resistance to temperature, pressure, and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If known electric feedthroughs are used in high temperature environments, then electrical current conduction is achieved, but thermal stress and material degradation lead to device failure
Solution Approach 1:
The feedthrough assembly uses a composite structure combining ceramic insulating material with metal components (stainless steel or Inconel). The ceramic material provides thermal insulation and electrical isolation while the metal components provide structural strength and electrical conduction. This composite approach allows the device to withstand high temperatures without compromising reliability.
Solution Approach 2:
The patent specifies that the feedthrough is designed to operate at temperatures up to 600°C, representing a significant parameter change from conventional feedthroughs. The ceramic insulating material and high-temperature alloy components are selected specifically to maintain their structural and electrical properties at this elevated temperature range.
2Stress or pressure
If known electric feedthroughs are used in high pressure environments, then electrical current conduction is achieved, but mechanical stress leads to device failure
Solution Approach 1:
The combination of ceramic insulating material with high-strength metal components creates a composite structure that distributes mechanical stress across different materials with complementary properties. The ceramic provides compressive strength while the metal components provide tensile strength and ductility.
Solution Approach 2:
Different materials are used in different regions of the feedthrough assembly based on local stress requirements. The metal components are positioned where tensile and shear stresses are highest, while the ceramic material is used where compressive strength and electrical insulation are most critical.
3Object-affected harmful factors
If known electric feedthroughs are used in corrosive environments, then electrical current conduction is achieved, but chemical attack from heated ammonia leads to device failure
Solution Approach 1:
The ceramic insulating material provides chemical inertness and resistance to corrosion from heated ammonia, while the stainless steel or Inconel metal components provide structural integrity and additional corrosion resistance through their alloy composition. This composite structure protects against chemical attack better than conventional single-material feedthroughs.
Solution Approach 2:
The feedthrough is designed as a replaceable component that can be installed and removed from the pressure vessel. When exposed to corrosive environments, the entire assembly can be replaced rather than attempting to repair damaged components, ensuring continued reliability in corrosive service.
4Force
If known electric feedthroughs are used in high vibration environments, then electrical current conduction is achieved, but mechanical stress from vibration leads to device failure
Solution Approach 1:
The composite structure of ceramic and metal components provides inherent vibration damping through the interaction between the two materials. The ceramic material absorbs high-frequency vibrations while the metal components provide structural flexibility to accommodate low-frequency vibrations.
Solution Approach 2:
The feedthrough design incorporates flexible sealing elements and mounting arrangements that allow the assembly to accommodate vibration-induced movements without compromising the electrical connection or sealing integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The assembly effectively conducts electric currents in high temperature, high pressure, and corrosive environments, providing reliable power to catalyst units by mitigating thermal and mechanical stress while resisting chemical attack, thus extending the operational lifespan and ensuring device integrity.
Implementation Method 1
when known electric feedthroughs are exposed to high temperatures which are significantly higher than those at which its components were assembled, these components expand by different amounts due to differences in coefficient of thermal expansion
Implementation Method 2
The insulating material can in turn be surrounded by a metal sleeve
Implementation Method 3
Heated ammonia is known to be especially corrosive, and is characterized by its ability to attack and damage many materials, including steel, stainless steel, copper, brass, aluminum, rubbers, and plastics
Data Source
AI summary
The present invention relates, in general, to an apparatus for an electrical power feedthrough suitable for use in high temperature, high pressure, and/or corrosive environments, such as, for example, within ammonia cracking (i.e., dissociation) systems. The present invention is fabricated from conductive nickel alloys which have high melting temperatures, and which are resistant to corrosion at high temperatures, as well as non-conductive ceramic materials which provide electrical insulation between the systems that feedthrough is coupled to.