Electrically Heated SMR Reactors for Rapid Condition Switching

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Solution Overview

Problem

Steam methane reforming (SMR) reactors are difficult to start-up and transition between steady-state reaction conditions due to the need for precise temperature control and heating, leading to complex operation and slow changes in reaction conditions.

Innovation Solution

A reactor system with a structured catalyst comprising an electrically conductive macroscopic structure coated with a ceramic material, heated internally by electrical current, allowing rapid switching between steady-state conditions by adjusting electrical power and gas flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If external combustion heating is used for steam methane reforming, then the reactor can achieve the required temperature for the endothermic reaction, but the system becomes complex and difficult to control due to balancing two chemical reactors

Engineering Contradiction:

Improvereaction temperatureVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The invention extracts the heating function from the external combustion reactor and implements it as an independent electrical heating system. This separates the reforming reaction from the heating process, eliminating the need to balance two chemical reactors while maintaining the required temperature for the endothermic steam methane reforming reaction.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention replaces the mechanical/chemical heating system (external combustion) with an electrical heating system. This substitution simplifies control by allowing independent adjustment of heating power through electrical parameters, eliminating the complexity of balancing combustion and reforming reactions simultaneously.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If multiple parallel tubes are used to increase capacity, then the reactor can process larger gas flows, but the operation becomes tedious and complex due to the need to maintain even heat and gas distribution

Engineering Contradiction:

Improvegas processing capacityVSAvoidoperational simplicity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The invention merges the heating function into a single integrated electrical heating system that uniformly heats the catalyst bed. This eliminates the need for multiple parallel tubes with individual heating control, simplifying operation while maintaining the capacity to process large gas flows through the unified reactor design.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If external combustion heating is used, then the reactor can maintain steady-state operation, but transitions between steady-state conditions are slow due to the time required to balance heating and heat consumption

Engineering Contradiction:

Improvesteady-state stabilityVSAvoidtransition time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The invention replaces the slow thermal response of external combustion heating with rapid electrical heating. Electrical power can be adjusted quickly and precisely, enabling fast transitions between steady-state conditions while maintaining stable operation, thus reducing the time penalty associated with state changes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If preheating of large amounts of non-reactive gas is performed, then ATR technology can avoid excessive sooting, but the utility systems become larger and more complex

Engineering Contradiction:

Improvesooting preventionVSAvoidutility system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts the heating function from the utility systems and implements it directly within the reactor through electrical heating. This eliminates the need for external preheating of large amounts of non-reactive gas, preventing sooting while simplifying the utility systems and reducing their size and complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables rapid and efficient switching between reaction conditions, reducing the complexity and time required for start-up and operation, while maintaining precise temperature control and minimizing reactor size.

Implementation Method 1

supplying electrical power to the structured catalyst, thereby heating the structured catalyst to a first temperature

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a structured catalyst arranged to catalyze steam reforming of a feed gas comprising hydrocarbons

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

wherein said reactor system is provided with heat insulation between said structured catalyst and said pressure shell

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12410054B2Synthesis gas on demand

Publication Date: 2025.09.09 HALDOR TOPSOE AS

AI summary

A method is provided for rapidly switching a metal-catalysed steam methane reforming reaction of a feed gas from a first steady-state reaction condition (A) to a second steady-state reaction condition (B) or vice-versa. After applying a given voltage and/or feed gas flow, the system can work towards a thermal equilibration to reach steady state without any additional operator input.