3D Carbon Nanostructured Foam for Volumetric Microwave Heating

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Solution Overview

Problem

Conventional heat exchangers in industrial applications, particularly in the Oil & Gas industry, are inefficient in heating non-polar substances like crude oil due to their inability to effectively absorb microwave radiation, leading to non-uniform heating and contamination issues with loosely dispersed carbon nanostructures.

Innovation Solution

A three-dimensional carbon nanostructured porous foam is used as a heat exchanger, capable of absorbing microwave energy and transferring heat efficiently to substances, offering high porosity and surface area for uniform heating and integration within fluid flows.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional heat exchangers are used to heat non-polar substances like crude oil, then the heating process can be performed, but the heating is non-uniform and inefficient due to inability to absorb microwave radiation

Engineering Contradiction:

Improveheating efficiencyVSAvoidheating uniformity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent employs a porous carbonaceous material with controlled pore structure that allows microwave penetration and uniform energy distribution throughout the crude oil, enabling efficient and uniform heating of non-polar substances that conventional heat exchangers cannot achieve

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The invention uses a composite system combining carbonaceous material with specific dielectric properties that enhances microwave absorption and heat transfer efficiency, creating a material that bridges the gap between microwave interaction and thermal transfer for non-polar fluids

Inventive Principle:

Principle #40Composite materials

2Use of energy by moving object

If loosely dispersed carbon nanostructures are used for microwave heating, then heating capability is improved, but contamination issues arise

Engineering Contradiction:

Improvemicrowave absorptionVSAvoidcontamination

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The porous structure of the carbonaceous material provides a fixed, stable framework that prevents contamination of crude oil while maintaining effective microwave absorption and heat transfer capabilities throughout the processing system

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent employs a stable, non-dispersing carbonaceous material that eliminates contamination risks associated with loose nanostructures, providing a durable solution that maintains its structural integrity throughout the heating process

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Device complexity

If conventional heat exchangers are used, then the system structure is simple, but the heating process is slow and energy inefficient

Engineering Contradiction:

Improvesystem structureVSAvoidheating speed

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The invention replaces conventional mechanical heat transfer systems with a microwave-based heating system using porous carbonaceous material, enabling rapid and efficient energy transfer that significantly reduces heating time while maintaining relatively simple system architecture

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 three-dimensional carbon nanostructured porous foam enables rapid, selective, and uniform heating of substances, enhancing the efficiency of processes like crude oil refining and reducing contamination risks, making it suitable for large-scale industrial applications.

Implementation Method 1

capable of absorbing microwave energy and transferring heat efficiently to substances

Methodology Applied

Scientific EffectDielectric heating: Dielectric Heating

Implementation Method 2

exposed to an electronic energy source... The nanostructured porous carbon foam acts as a heat transfer material to the substance

Methodology Applied

Scientific EffectMicrowave radiation absorption: Absorption (EM radiation)

Implementation Method 3

The nanostructured porous carbon foam acts as a heat transfer material to the substance... resulting in a selectable physical or chemical transformation

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12035448B2Dielectric heating of three-dimensional carbon nanostructured porous foams as a heat exchanger for volumetric heating of flowing fluids

Publication Date: 2024.07.09 HASHIM DANIEL PAUL

AI summary

A system and method are described for heating a substance (i.e., liquid, gas, and/or an absorbed solid) using a carbon nanostructured porous foam as a heat transfer material and an electronic heat source. In some embodiments, the heat source may be a microwave volumetric heating (MVH) system. The method for heating, vaporizing, or decomposing any of the desired substance may involve filtering or continuously flowing the substance through the carbon nanostructured porous foam heat transfer material, resulting in physical confinement or absorption of the substance, and subjecting the carbon nanostructure porous foam heat transfer material to sufficient electronic radiation.