Electrically Heated Reactor With Direct Catalyst Heating
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Solution Overview
Problem
Conventional reactors that heat catalysts using combustion heat are inefficient and contribute to carbon emissions, making them unsuitable for addressing the climate change crisis.
Innovation Solution
An electrically heated reactor design where a catalyst is coated on a heat transfer member thermally connected to an electrically heated heating plate, allowing direct heating of the catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If natural gas combustion is used to heat facilities, then high temperatures are maintained, but energy efficiency is poor and carbon emissions increase
Solution Approach 1:
The patent replaces the mechanical/chemical combustion heating system with an electrical heating system. The electrical heating plate directly converts electrical energy to thermal energy, eliminating the need for natural gas combustion and improving energy efficiency while maintaining the required temperature levels for industrial facilities.
Solution Approach 2:
The patent extracts and eliminates the combustion heating component from the system. By removing the natural gas combustion process and replacing it with direct electrical heating, the system eliminates carbon emissions and improves energy efficiency while maintaining temperature control capabilities.
2Temperature
If natural gas combustion is used to heat facilities, then high temperatures are maintained, but carbon emissions increase
Solution Approach 1:
The patent substitutes the combustion-based heating system with an electrical heating system. This replacement eliminates the combustion process that generates carbon emissions, thereby removing the harmful environmental factor while preserving the temperature maintenance function required for industrial operations.
Solution Approach 2:
The patent converts the harmful combustion process into a beneficial electrical heating process. By replacing the carbon-emitting combustion system with clean electrical heating, the system transforms an environmentally harmful approach into an environmentally friendly solution that maintains operational effectiveness.
3Temperature
If heat exchange medium is used to heat catalyst, then heating is achieved, but energy efficiency is poor due to indirect heating
Solution Approach 1:
The patent extracts and removes the heat exchange medium from the heating process. By eliminating the intermediate heat transfer step, the system achieves direct heating of the catalyst support, removing the energy losses associated with heating and circulating the heat exchange medium.
Solution Approach 2:
The patent creates an asymmetric heating approach where the heating plate directly contacts and heats only the catalyst support structure, rather than symmetrically heating the entire reaction environment. This targeted asymmetric heating reduces energy consumption by focusing thermal energy only where needed.
4Temperature
If heat exchange medium is used to heat catalyst, then heating is achieved, but energy consumption increases
Solution Approach 1:
The patent removes the heat exchange medium from the system, eliminating the energy consumption associated with pumping, heating, and circulating the medium. The direct electrical heating of the catalyst support drastically reduces the total energy consumption while maintaining effective catalyst heating.
Solution Approach 2:
The heating plate directly heats the catalyst support without requiring an external heat exchange medium. This self-service heating approach eliminates the need for additional energy-consuming components such as pumps and heat exchangers, reducing overall energy consumption.
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
Improves energy efficiency by directly heating the catalyst, reduces energy consumption, and maintains uniform temperature, preventing hot or cold spots.
Implementation Method 1
a heating plate disposed on one side or the other side of the housing and generating heat by receiving current from a power source
Implementation Method 2
at least one heat transfer member extending from the heating plate toward the other side or one side in the first direction, having a catalyst coated on a surface, and transferring heat generated from the heating plate toward the other side or the one side in the first direction to heat the catalyst
Data Source
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AI summary
An electrically heated reactor is disclosed. The electrically heated reactor includes a housing having a housing inlet formed on one side portion in a first direction into which a reactant flows, and a housing outlet formed on the other side portion in the first direction from which a reacted product is discharged, a heating plate disposed on one side portion or the other side portion of the housing and generating heat by receiving current from a power source, and at least one heat transfer member extending from the heating plate toward the other side or one side in the first direction, having a catalyst coated on a surface, and transferring heat generated from the heating plate toward the other side or the one side in the first direction to heat the catalyst.