Electric Reactor Heating Elements with Inert Atmosphere
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Solution Overview
Problem
Current chemical reactor processes using fired reactors face challenges in reducing local carbon dioxide emissions and are economically inefficient for producing olefins, synthesis gas, and hydrogen, as they rely on fossil fuels, and indirect electrical heating methods require high heat flux densities that can damage heating elements.
Innovation Solution
A reactor arrangement using radiant heat from electric heating elements within a thermally insulated reactor vessel, maintaining a gas atmosphere with a controlled oxygen volume fraction between 500 ppm and 10% to protect heating elements and ensure operational safety, while allowing for a wide temperature range of 400°C to 1500°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If indirect electrical heating using radiant heaters is used to heat reaction tubes, then carbon dioxide emissions are reduced and operational flexibility is improved, but the heating elements are damaged due to high heat flux densities
Solution Approach 1:
The patent applies this principle by introducing a gas atmosphere with controlled oxygen content (500 ppm to 10% by volume) surrounding the heating elements. This atmosphere prevents excessive oxidation of the heating elements while maintaining the high temperatures (400°C to 1500°C) needed for the chemical reactions in the reaction tubes, thereby protecting the heating elements from damage due to high heat flux densities.
2Reliability
If oxygen content in the gas atmosphere is increased to protect heating elements from corrosion, then heating element durability is improved, but the risk of explosions and pressure increases rises
Solution Approach 1:
The patent applies this principle by precisely controlling the oxygen content parameter within a specific range (500 ppm to 10% by volume). This optimized parameter range is sufficient to maintain a protective oxide layer on the heating elements, preventing corrosion, while remaining below the thresholds that would create explosive conditions with hydrocarbon process gases, thus balancing element protection with safety.
3Ease of operation
If fired reactors using fossil fuels are used for chemical reactions, then operational simplicity is maintained, but carbon dioxide emissions increase and economic efficiency decreases
Solution Approach 1:
The patent applies this principle by replacing the mechanical combustion system (fired reactors using fossil fuels) with an electrical heating system using radiant heaters. This substitution eliminates carbon dioxide emissions from fuel combustion while maintaining the ability to achieve and control the high temperatures required for endothermic chemical reactions, thereby resolving the contradiction between operational simplicity and environmental impact.
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
This approach enhances the durability of heating elements and operational safety by preventing corrosion and maintaining a stable oxide layer, reducing the risk of explosions and pressure increases, and allows for efficient production of olefins and synthesis gases with reduced carbon emissions.
Implementation Method 1
reaction tubes arranged in a reactor vessel are heated to a reaction tube temperature level between 400° C. and 1,500° C. during a reaction period using radiant heat provided by means of one or more electric heating elements
Data Source
AI summary
A method for carrying out a chemical reaction includes using a reactor arrangement in which reaction tubes arranged in a reactor vessel are heated to a reaction tube temperature level between 400° C. and 1,500° C. during a reaction period using radiant heat provided by means of one or more electric heating elements arranged in the reactor vessel. In at least a part of the reactor vessel in which the heating elements are provided, a gas atmosphere is provided during the reaction period, which gas atmosphere has a defined volume fraction of oxygen.