Electric braking resistor-based heat generator for process fluids and emulsions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional process heaters, such as natural draft burner-based fire tubes and immersion heaters, face challenges including inefficiencies in combustion, harmful emissions, high maintenance costs, and the inability to operate safely in environments with flammable gases or emulsions.
Innovation Solution
An electric braking resistor-based heat generator is introduced, which uses an electrically powered braking resistor as the heat source. This system is designed to convert electrical energy into thermal energy without the need for gas-based fuels or flames, and it is physically isolated from the process fluids or emulsions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If natural draft burner-based fire tubes are used for heating process fluids, then heating capability is provided, but harmful emissions are generated and combustion efficiency is reduced
Solution Approach 1:
The patent replaces the combustion-based heating system (fire tubes) with an electric heating element system. This substitution eliminates the combustion process entirely, removing the source of harmful emissions while improving energy efficiency through direct electrical heating of the process fluid or heating medium.
Solution Approach 2:
The invention changes the fundamental operating parameter from chemical combustion to electrical heating. By transitioning from a chemical energy conversion process (combustion) to an electrical energy conversion process (resistive heating), the system eliminates emissions and improves energy efficiency.
2Productivity
If immersion heaters are used to heat process fluids, then heating efficiency is improved, but maintenance costs increase and safety issues arise in flammable environments
Solution Approach 1:
The patent introduces a heating medium (such as thermal oil or water) as an intermediary between the electric heating element and the process fluid. The heating medium absorbs heat from the electric element and transfers it to the process fluid through a heat exchange surface, eliminating direct contact between the heating element and the process fluid, thereby reducing maintenance and safety issues.
3Ease of operation
If conventional process heaters are used, then heating capability is provided, but device complexity and maintenance requirements increase
Solution Approach 1:
The patent extracts and eliminates the complex combustion system (burners, fire tubes, air supply systems) from the heating apparatus, replacing it with a simpler electric heating element system. This extraction of the combustion subsystem significantly reduces device complexity and maintenance requirements while maintaining heating capability.
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 electric braking resistor-based heat generator achieves high efficiency in converting electrical energy to thermal energy, eliminates harmful emissions, reduces maintenance costs, and allows safe operation in environments with flammable substances.
Implementation Method 1
The electric braking resistor converts electrical energy provided by an electric power source into thermal energy
Implementation Method 2
a thermally conductive material disposed within the enclosed portion of the housing that provides thermal communication between the electric braking resistor and the housing
Data Source
AI summary
An electric braking resistor-based heat generator for process fluids or emulsions includes a housing having a connection end, a body portion, and a closed end, where at least part of the housing forms an at least partially enclosed portion, an electric braking resistor at least partially disposed within the enclosed portion of the housing, and a thermally conductive material disposed within the enclosed portion of the housing that provides thermal communication between the electric braking resistor and the housing. The electric braking resistor converts electrical energy provided by an electric power source into thermal energy that is thermally communicated from the housing to the process fluids or emulsions.