Electrical Reforming Reactor with Structured Catalytic Module
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Solution Overview
Problem
Existing fired reformers for steam methane reforming face challenges such as high energy consumption, significant temperature gradients, and heat loss, making them inefficient and environmentally unfriendly, especially when trying to retrofit existing systems into electrically heated reactors.
Innovation Solution
An electrical reforming reactor design featuring a structured catalytic module with an open tubular shape and concertina structure, where electrical conductor members are arranged along the axial edges, and insulation members ensure even current distribution and minimize heat loss, allowing for direct heat delivery to the catalyst, reducing energy losses and improving current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional fired reformers are used to provide high temperatures for steam methane reforming, then acceptable methane conversion is achieved, but high energy consumption and significant heat loss occur
Solution Approach 1:
The patent combines the heating function and catalytic reaction function into a single integrated reactor system. The electric heating elements are positioned in direct thermal contact with the catalyst beds, merging the heat source and reaction zone to eliminate heat transfer losses through reactor walls and intermediaries.
Solution Approach 2:
The patent replaces the mechanical combustion-based heating system with an electrical heating system. Electric heating elements substitute for burners and flame-based heat sources, providing more efficient and controllable heat delivery directly to the catalyst beds without the energy losses associated with conventional fired heating.
2Temperature
If large temperature gradients are present in fired reactors, then high temperatures are achieved, but heat transfer resistance increases and efficiency decreases
Solution Approach 1:
The patent applies local heating zones with electric heating elements positioned at specific locations within the reactor to match the thermal requirements of different catalyst beds. This localized heating approach eliminates large temperature gradients by providing heat exactly where needed, reducing heat transfer resistance and improving overall efficiency.
3Object-affected harmful factors
If conventional fired reactors are retrofitted to electrical heating, then environmental friendliness improves, but system complexity and modification difficulty increase
Solution Approach 1:
The patent divides the reactor into modular sections with discrete electric heating elements and catalyst beds. This segmentation allows for incremental retrofitting where individual modules can be replaced or modified independently, reducing the overall complexity and difficulty of converting existing fired reactors to electrical heating systems.
4Productivity
If catalyst surface density is increased to improve reaction efficiency, then conversion rates increase, but heat transfer and current distribution challenges arise
Solution Approach 1:
The patent introduces electrically conductive supports as intermediaries between the heating elements and the catalyst. These supports facilitate uniform current distribution across high-density catalyst beds while maintaining efficient heat transfer, allowing increased catalyst surface density without compromising electrical or thermal performance.
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 design significantly reduces energy losses and temperature gradients, enhances reaction efficiency by minimizing mass and heat transfer resistances, increases catalyst surface density, and allows for flexible and cost-effective scaling, making it suitable for both new and existing reactor installations.
Implementation Method 1
The steam reforming reaction is highly endothermic. High temperatures typically in excess of 800-850°C are needed to reach acceptable conversions of the methane in the feed.
Implementation Method 2
a thermal insulation member (20) arranged between the outer tubular vessel and the structured catalytic module(s)
Implementation Method 3
The heat is then immediately delivered to the catalyst which is either coated over the wall/element like an internal lining is filled inside the volume surrounded by the said wall.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Reforming reactor for reforming a feed gas comprising hydrocarbons, comprising an outer tubular vessel (25) containing at least one structured catalytic module comprising: • A structured catalyst (1) having an open tubular shape with two axial parallel edges and a concertina structure, and comprising at least one electrically conductive material supporting at least one catalyst, • At least two electrical conductor members (5a) and (5b) arranged along the two axial edges of the structured catalyst, and • At least a first electrical insulation member (11) arranged between the conductor members for electrically insulating them from each other.