Electric heater and method for providing process heat
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Solution Overview
Problem
Industrial processes requiring high-temperature process heat above 1000 °C, such as in steel and cement production, rely heavily on fossil fuels, leading to significant CO2 emissions, with no cost-competitive or easily integratable alternative solutions available to decarbonize high-temperature heat generation.
Innovation Solution
An electric heater system that uses active ceramic resistance heating elements and passive thermal elements made of ceramic materials to heat a gaseous fluid stream to 1000 °C or more, allowing for the conversion of renewable electricity into process heat, thereby reducing CO2 emissions and providing a cost-effective, environmentally friendly alternative.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fossil fuels are used to generate process heat above 1000 °C, then high-temperature heat can be generated, but CO2 emissions increase significantly
Solution Approach 1:
The patent replaces the chemical combustion system (fossil fuel burners) with an electrical heating system using ceramic resistance elements. This substitution eliminates CO2 emissions while achieving the required temperatures of 1000-1500°C for industrial processes.
Solution Approach 2:
The patent changes the energy source parameter from chemical energy (fossil fuels) to electrical energy, and uses ceramic materials with specific electrical and thermal properties to enable high-temperature operation without combustion, thus resolving the contradiction between temperature generation and emission reduction.
2Object-generated harmful factors
If ceramic resistance heating elements are used to generate high-temperature process heat, then CO2 emissions are reduced, but the active elements have limited lifespan due to material degradation
Solution Approach 1:
The patent introduces passive thermal elements as intermediaries between the active ceramic resistance elements and the process fluid. These passive elements absorb heat from the active elements and transfer it to the fluid, reducing thermal stress and oxidation on the active elements, thereby extending their operational life while maintaining emission-free operation.
Solution Approach 2:
The passive thermal elements serve as a protective buffer that shields the active heating elements from direct exposure to harsh operating conditions (high temperature, oxidation, fluid flow), preventing premature degradation and extending service life.
3Duration of action of stationary object
If passive thermal elements are added to extend active element lifespan, then active element degradation is reduced, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the passive thermal elements: they serve as heat transfer mediators, protective shields for active elements, structural support components, and flow distribution elements. This merging reduces the need for separate components and simplifies the overall system design despite the addition of passive elements.
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 heater system efficiently generates high-temperature process heat with reduced CO2 emissions, offering a cost-effective and easily integratable solution for industries, enabling the use of renewable energy sources like solar or wind electricity, and reducing operational costs through increased efficiency and extended active element lifespan.
Implementation Method 1
The first heating stage comprises one or more first active ceramic resistance heating elements that are arranged and configured for generating heat with a first temperature of 1000 °C or more, when applying an electric current to the one or more first active ceramic resistance heating elements
Implementation Method 2
The first heating stage comprises at least one passive thermal element, preferably, comprising a ceramic material, that is arranged and configured for passively heating the gaseous fluid stream to the temperature of 1000 °C or more and/or for storing heat generated by the one or more first active ceramic resistance heating elements
Implementation Method 3
at least one passive thermal element, preferably, comprising a ceramic material, that is arranged and configured for passively heating the gaseous fluid stream
Data Source
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AI summary
The present invention relates to an electric heater for providing process heat by electrically heating a gaseous fluid stream to a temperature of 1000 °C or more is proposed. The electric heater comprises a heating chamber having a gas inlet configured for providing the gaseous fluid stream to inside the heating chamber and a gas outlet configured for providing the gaseous fluid stream having a temperature of more than 1000 °C to outside the heating chamber. The electric heater further comprises a first heating stage housed in the heating chamber. The first heating stage comprises one or more first active ceramic resistance heating elements that are arranged and configured for generating heat with a first temperature of 1000 °C or more, when applying an electric current to the one or more first active ceramic resistance heating elements. Moreover, the first heating stage comprises at least one passive thermal element that is arranged and configured for passively heating the gaseous fluid stream to the temperature of 1000 °C or more and/or for storing heat generated by the one or more first active ceramic resistance heating elements.