Electric Heating Reactor With Internal Element for Uniform Tube Heating
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Solution Overview
Problem
Existing electric direct-heating reactors face inefficiencies in uniformly heating the reactor interior, leading to cold spots that can cause coking and shorten catalyst lifespan in endothermic reactions.
Innovation Solution
An electric heating reactor design with a heating element inside the reaction tube, connected to a power source via conductive sockets, generates heat uniformly by adjusting resistances of the reaction tube and heating element to control heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If a current is applied to a tubular reactor having high resistivity to heat the reactor itself, then the reactor can be heated by electric direct-heating method, but heat cannot be uniformly transferred to the center of the reactor and cold spots occur
Solution Approach 1:
The heating function is segmented between two components: the reaction tube wall (outer heating) and the heating element (inner heating). This segmentation allows heat to be generated at multiple locations simultaneously, ensuring uniform temperature distribution throughout the reaction tube interior and eliminating cold spots.
Solution Approach 2:
The heating approach transitions from single-dimensional (external heating only) to multi-dimensional by placing a heating element inside the reaction tube. This internal heating element adds a new heating dimension from the center outward, working in conjunction with the external heating to achieve uniform temperature distribution.
2Temperature
If natural gas combustion is used to maintain high temperature in chemical facilities, then heating can be achieved, but energy consumption is inefficient and carbon emissions increase
Solution Approach 1:
The thermal system replaces the chemical combustion system. Instead of using natural gas combustion (chemical energy conversion), the invention uses electric current passing through resistive elements (electrical energy conversion to thermal energy). This substitution eliminates carbon emissions from fuel combustion while achieving the required high temperatures for endothermic reactions.
3Temperature
If natural gas combustion is used to maintain high temperature in chemical facilities, then heating can be achieved, but carbon emissions are generated
Solution Approach 1:
The thermal system replaces the chemical combustion system. Instead of using natural gas combustion (chemical energy conversion), the invention uses electric current passing through resistive elements (electrical energy conversion to thermal energy). This substitution eliminates carbon emissions from fuel combustion while achieving the required high temperatures for endothermic reactions.
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
Uniform heating of the reactor interior suppresses cold spots, ensuring consistent reaction conditions and extending catalyst lifespan.
Implementation Method 1
a power source configured to supply power to the reaction tube to heat the reactant passing through the passage
Implementation Method 2
a heating element extending inside the reaction tube in the length direction, electrically connected to the reaction tube, and configured to generate heat by receiving the power supplied from the power source and further heat the reactant passing through the passage
Data Source
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AI summary
Disclosed is an electric heating reactor. The reactor includes: a reaction tube including a passage formed therein in a length direction, through which a reactant passes; a power source configured to supply power to the reaction tube to heat the reactant passing through the passage; a pair of conductive sockets configured to connect the power source to the reaction tube to enable current flow; and a heating element extending inside the reaction tube in the length direction, electrically connected to the reaction tube, and configured to generate heat by receiving power supplied from the power source and further heat the reactant passing through the passage.