Catalytic U-Shaped Tank Heating Coil for Low-Emission Heating
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Solution Overview
Problem
Conventional tank heating methods, such as direct-fired gas heaters, result in energy wastage and environmental byproducts, as they rely on burning gas to heat storage tanks for oil and production fluids, especially in cold climates or with waxy fluids, necessitating a more efficient and environmentally friendly heating solution.
Innovation Solution
A system utilizing a U-shaped pipe with a catalyst unit embedded within, comprising a catalyst-wrapped, natural gas-filled, perforated pipe that enables a catalytic reaction on its exterior, combined with mechanical controls to vary temperature output, and a vent pipe for air circulation, facilitating a self-sustaining catalytic reaction that produces heat, carbon dioxide, and water, with reduced smog-causing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If direct-fired gas heaters are used to heat storage tanks, then the tanks can be heated effectively, but energy is wasted and environmental byproducts are generated
Solution Approach 1:
The patent converts the harmful waste heat from direct-fired gas heaters into a beneficial resource by capturing it through heat exchangers and redirecting it back to the tank. This transforms the harmful thermal pollution into useful heating energy, reducing overall energy consumption while maintaining effective tank heating
Solution Approach 2:
The system recovers waste heat that would otherwise be discarded into the atmosphere through stacks. Heat exchangers capture this wasted thermal energy and reuse it for tank heating, thereby reducing energy wastage while maintaining heating effectiveness
2Temperature
If direct-fired gas heaters are used to heat storage tanks, then the tanks can be heated effectively, but environmental byproducts and smog-causing emissions are produced
Solution Approach 1:
The patent converts harmful emissions into a benefit by using heat exchangers to capture thermal energy from exhaust gases before they are released. This allows the system to maintain effective heating while reducing the release of harmful byproducts into the environment
Solution Approach 2:
Heat exchangers serve as intermediary devices between the direct-fired heater and the environment. They mediate the heat transfer process by extracting useful energy from exhaust gases before discharge, thereby reducing harmful emissions while maintaining heating effectiveness
3Stability of the object's composition
If continuous heating is applied to maintain fluid in liquid state, then the fluid remains in liquid state, but energy consumption increases
Solution Approach 1:
The patent implements continuous useful action by recirculating heated fluid through heat exchangers that continuously transfer thermal energy back to the tank. This continuous thermal recycling maintains fluid in liquid state more efficiently than intermittent heating, reducing overall energy consumption while ensuring continuous stability
Solution Approach 2:
The system employs feedback mechanisms where temperature sensors monitor fluid state and control systems adjust heating intensity accordingly. Heat exchangers provide continuous thermal feedback to maintain optimal temperature, ensuring fluid remains in liquid state only when necessary, thereby reducing unnecessary energy consumption
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 system provides efficient heat production with reduced environmental impact by using a catalytic reaction that is self-sustaining and minimizes energy wastage, maintaining the fluid in a liquid state without the need for continuous heating, while also reducing emissions.
Implementation Method 1
a catalyst unit embedded within the U-shaped pipe, the catalyst unit comprising a catalyst wrapped, natural gas filled, perforated pipe that is configured to enable a catalytic reaction on its exterior
Implementation Method 2
an insulated segment of wire running generally back up along the entire length of the catalyst insert
Data Source
AI summary
A system includes a tank containing a fluid to be heated; a U-shaped pipe disposed proximate a bottom of the tank, a majority of the extent of the U-shaped pipe being disposed within an interior of the tank; a catalyst unit embedded within the U-shaped pipe, the catalyst unit comprising a catalyst wrapped, natural gas filled, perforated pipe that is configured to enable a catalytic reaction on its exterior; a vent pipe attached to the U-bend pipe which allows air to circulate; and mechanical controls disposed proximate the U-shaped pipe configured to vary temperature output.