Electrically Heated Reactor Tube Feed for Low-Loss Current Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrically heated reactors face challenges in efficiently supplying high current flows and managing high temperatures due to the need for low-loss current feed to reaction tubes, particularly in processes requiring endothermic reactions like steam cracking, where conventional heating methods result in high carbon dioxide emissions.
Innovation Solution
The reactor design includes current feed arrangements with first and second sections that surround or are surrounded by each other obliquely, extending through the reactor vessel wall, allowing for efficient electrical heating of reaction tubes using multi-phase alternating or direct current, minimizing thermal losses and ensuring stable, low-resistance current transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional fired heating is used in reactors, then high temperatures are achieved, but carbon dioxide emissions increase
Solution Approach 1:
The patent replaces the mechanical/chemical combustion heating system with an electrical heating system. Current feed arrangements conduct electricity directly through the reaction tubes, generating heat via Joule heating. This substitution eliminates the need for fossil fuel combustion while achieving the required high temperatures for endothermic reactions, thereby resolving the contradiction between temperature achievement and CO2 emission reduction.
Solution Approach 2:
The patent changes the heating method parameter from combustion-based thermal input to electrical current-based thermal input. By controlling electrical parameters (voltage, current, phase) and transforming them into thermal energy within the reaction tubes, the system achieves temperature control without producing harmful emissions, thus resolving the technical contradiction.
2Power
If high current flows are supplied to reaction tubes, then efficient electrical heating is achieved, but thermal losses and temperature management become challenging
Solution Approach 1:
The current feed arrangements feature a nested structure where a first section and a second section surround or are surrounded by each other in a sleeve-like manner. This nested design allows for efficient current conduction while providing thermal insulation and protecting against heat loss. The concentric arrangement minimizes thermal losses by containing the heat within the reaction tubes while still allowing high current flows for efficient heating.
Solution Approach 2:
The current feed arrangements act as intermediaries between the electrical power source and the reaction tubes. The multi-section structure with oblique contact surfaces provides a low-resistance current path while managing thermal transitions, thus enabling efficient power transfer while minimizing energy loss through optimized thermal management at the interface.
3Ease of manufacture
If current feed arrangements use simple linear contact, then manufacturing is easier, but current transfer resistance increases and stability decreases
Solution Approach 1:
The current feed arrangements utilize oblique (angled) contact surfaces instead of simple linear contacts. This curved/angled geometry increases the contact area between sections, reducing contact resistance and improving current transfer stability. The oblique design maintains manufacturing feasibility while significantly enhancing electrical connection reliability through increased surface contact.
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 enables efficient, low-loss current supply to reaction tubes, maintaining stable temperatures and reducing thermal stress, thereby enhancing the efficiency and safety of endothermic chemical reactions while minimizing carbon dioxide emissions.
Implementation Method 1
tube sections are each electrically connected or connectable to one or more current connections in a current feed region for electrically heating the tube sections
Data Source
AI summary
A reactor has a reactor vessel and a reaction tube. Tube sections of the reaction tube run inside the reactor vessel. The tube sections are each electrically connectable to a current connection in a current feed region. Current feed arrangements are arranged in the current feed region to which in each case one or one group of the tube sections is electrically connected. Each current feed arrangement has a first and a second section, the first section extending along a longitudinal axis starting from the respective or group of tube section(s). The first section at least partially surrounds the second section or the second section surrounds the first section in a sleeve-like manner. The first and second sections each have contact surfaces arranged obliquely to the longitudinal axis. The current feed arrangements each extend through a wall of the reactor vessel.