Counterflow Reactor Heat Exchange for High-Temperature Fluid Use
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Solution Overview
Problem
Existing reactors face challenges in effectively utilizing high-temperature fluids for preheating due to temperature mismatches between the high-temperature fluid and the required temperature for the preheating process.
Innovation Solution
A reactor design incorporating a heat exchange unit with a counter flow-type structure, featuring stacked plate-like heat transfer bodies with alternating reaction and heat medium flow channels, allowing for efficient heat transfer between a reaction fluid and a high-temperature heat medium, thereby promoting endothermic reactions and effectively utilizing the high-temperature fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat exchanger is provided independently of the reactor for preheating gas, then the preheating function is achieved, but the high-temperature fluid cannot be effectively utilized when the required preheating temperature is lower than the high-temperature fluid temperature
Solution Approach 1:
The patent combines the preheating function with the reactor by integrating a heat exchange unit directly into the reactor structure. The heat exchange unit includes heat transfer bodies with reaction flow channels and heat medium flow channels, allowing the high-temperature fluid to be used as a heat medium for preheating the reaction fluid within the reactor itself, thereby eliminating the need for a separate external heat exchanger and enabling effective utilization of the high-temperature fluid's thermal energy.
Solution Approach 2:
The heat exchange unit serves multiple functions simultaneously: it acts as both a reaction chamber and a heat exchanger. The high-temperature fluid flowing through the heat medium flow channels provides heat to the reaction fluid in the reaction flow channels, enabling the system to perform both chemical reaction and preheating operations within a single integrated structure.
2Productivity
If the high-temperature fluid is used for preheating in an independent heat exchanger, then the preheating process is completed, but the temperature mismatch reduces the effectiveness of high-temperature fluid utilization
Solution Approach 1:
The patent changes the operational parameters by allowing the high-temperature fluid to flow directly through the heat medium flow channels within the reactor at various temperatures. By adjusting the flow rate, temperature, and pathway of the high-temperature fluid through the stacked heat transfer bodies, the system can optimize heat transfer efficiency and effectively utilize the thermal energy across different temperature ranges, thereby improving productivity while minimizing exergy loss.
3Productivity
If a stacked-type reactor structure is used, then the reaction efficiency is improved, but the integration with preheating function requires additional external equipment
Solution Approach 1:
The patent merges the preheating equipment with the reactor by integrating the heat exchange unit into the stacked-type reactor structure. The heat transfer bodies are alternately stacked with reaction flow channels and heat medium flow channels, combining the reaction and preheating functions into a single integrated device, thereby eliminating the need for separate external preheating equipment while maintaining high reaction efficiency.
4Loss of energy
If the high-temperature fluid temperature is much higher than the required preheating temperature, then the high-temperature fluid has excess thermal energy, but this excess energy cannot be effectively utilized
Solution Approach 1:
The patent segments the heat exchange process by dividing it into multiple stages through the stacked heat transfer bodies. The high-temperature fluid flows through successive heat medium flow channels, transferring heat to the reaction fluid in each stage. This segmentation allows the excess thermal energy of the high-temperature fluid to be gradually utilized across multiple temperature gradients, effectively extracting thermal energy that would otherwise be wasted.
Solution Approach 2:
The patent adds a spatial dimension to heat transfer by using alternately stacked heat transfer bodies with multiple heat medium flow channels arranged in series. This three-dimensional stacked structure allows the high-temperature fluid to flow through multiple levels and channels, maximizing the surface area for heat transfer and enabling comprehensive utilization of thermal energy across different spatial zones, thereby addressing the temperature mismatch issue.
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 reactor achieves effective use of high-temperature fluids by maintaining and utilizing their thermal energy for both reaction promotion and preheating, enhancing the efficiency of the chemical process.
Implementation Method 1
a heat exchange unit (3) which executes a heat exchange between the reaction fluid (M) and the heat medium (HC) to promote a thermal reaction of a reaction raw material contained in the reaction fluid (M)
Implementation Method 2
The heat exchange unit (3) includes a first heat transfer body (7), a second heat transfer body (9), and a third heat transfer body (39) stacked on one another
Implementation Method 3
A reactor design incorporating a heat exchange unit with a counter flow-type structure, featuring stacked plate-like heat transfer bodies with alternating reaction and heat medium flow channels
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A reactor (1) includes first heat transfer bodies (7) including reaction flow channels (17) through which a reaction fluid (M) flows, second heat transfer bodies (9) stacked on the first heat transfer bodies (7) and including heat medium flow channels (31) through which a heat medium (HC) flows and product flow channels (70) through which a product (P) flows that is produced in the reaction flow channels (17) by a heat exchange between the reaction fluid (M) and the heat medium (HC), and product communication parts (46) including communication spaces (S3) through which the product (P) flows from the reaction flow channels (17) to the product flow channels (70).