Electrical Heating Reactor for Hydrocarbon Upgrading

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Solution Overview

Problem

Conventional reactor systems for upgrading hydrocarbons produce significant CO2 emissions and are prone to coke formation, leading to decreased production time and structural integrity issues due to coke deposition.

Innovation Solution

A reactor system using a heat transfer medium that converts electrical current to heat, positioned within a pressure containment vessel, to thermally treat hydrocarbon-containing streams, reducing coke formation and CO2 emissions by eliminating combustion-based heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If combustion-based heating is used in conventional reactor systems, then the hydrocarbon stream can be heated to required temperatures for upgrading, but CO2 emissions increase significantly

Engineering Contradiction:

Improveheating temperatureVSAvoidCO2 emissions

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the combustion-based thermal system with an electrical heating system. Electrical heaters directly convert electrical energy to heat within the reaction zone, eliminating the need for external combustion furnaces and thereby eliminating CO2 emissions from the heating process while maintaining the required temperature for hydrocarbon upgrading.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces electrical heaters as an intermediary device between the power source and the hydrocarbon stream. These heaters act as a mediator that transfers energy to the reaction zone without requiring combustion, thus achieving temperature control without generating CO2 emissions.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If conventional tubular reactors operate at high temperatures for hydrocarbon upgrading, then conversion efficiency improves, but coke formation increases leading to decreased production time

Engineering Contradiction:

Improveconversion efficiencyVSAvoidproduction time

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The patent applies local quality by providing heating directly within the reaction zone through electrical heaters embedded in the reactor. This localized heating ensures uniform temperature distribution throughout the hydrocarbon stream, preventing hot spots that would accelerate coke formation while maintaining the high temperatures needed for efficient conversion.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The electrical heating system enables continuous operation by maintaining stable, uniform temperatures that prevent coke formation. Unlike conventional systems that require periodic shutdowns for decoking, this system can operate continuously without interruption, maximizing production time and efficiency.

Inventive Principle:

Principle #20Continuity of useful action

3Temperature

If conventional tubular reactors are used for hydrocarbon upgrading, then the reactor structure can handle high temperatures, but coke deposition degrades metal surfaces leading to loss of structural integrity

Engineering Contradiction:

Improveoperating temperatureVSAvoidstructural integrity

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent replaces combustion-based external heating with internal electrical heating. This substitution eliminates the thermal stress gradients caused by external furnace heating, resulting in more uniform temperature distribution that reduces thermal fatigue and prevents coke-induced structural degradation over time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 system effectively converts hydrocarbons to desired products while minimizing CO2 emissions and extending the reactor's operational life by reducing coke formation, potentially decreasing CO2 production by millions of tons annually and minimizing the need for frequent decoking.

Implementation Method 1

supplying electrical current to the heat transfer medium; converting the electrical current to heat, thereby increasing the temperature of the heat transfer medium

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

heating the hydrocarbon-containing stream within the channels of the heat transfer medium

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS11679367B2Systems and processes for improving hydrocarbon upgrading

Publication Date: 2023.06.20 DOW GLOBAL TECHNOLOGIES LLC

AI summary

A reactor system for thermally treating a hydrocarbon-containing stream, that includes a pressure containment vessel comprising an interior chamber and a heat transfer medium that converts electrical current to heat and is positioned within the interior chamber of the pressure containment vessel, wherein the heat transfer medium comprises a first end face, a second end face, and channels extending between the first end face and the second end face. A process for thermally treating a hydrocarbon-containing stream includes introducing the hydrocarbon-containing stream into the reactor system, pressurizing the pressure containment vessel and the heat transfer medium without heating the pressure containment vessel or the heat transfer medium, supplying electrical current to the heat transfer medium, converting the electrical current to heat, heating the hydrocarbon-containing stream, and converting the hydrocarbon-containing stream to an effluent stream.