Electrically Heated Reactor with Radiative Heating Elements
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Solution Overview
Problem
Current industrial-scale chemical conversion processes face challenges in achieving high process efficiencies and cost-effectiveness, particularly in endothermic reactions, where conventional fossil fuel-based heating technologies are inefficient and environmentally unsustainable, necessitating the development of electrified gas conversion technologies that can handle high temperature and heat flux requirements.
Innovation Solution
A reactor configuration utilizing electrically heated furnaces with radiative heating elements, such as NiCr, SiC, MoSi2, and FeCrAl resistance heating elements, which allow for efficient heat transfer by radiation, convection, and conduction, enabling precise control of heat flux and temperature profiles, and incorporating inspection ports for monitoring reactor tubes during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional fossil fuel-based heating technologies are used for industrial-scale chemical conversion processes, then high temperature and heat flux requirements can be met, but process efficiency is low and CO2 production increases
Solution Approach 1:
The patent replaces conventional mechanical combustion-based heating systems with electrical heating elements. The electrical heating elements directly convert electrical energy to thermal energy through resistance heating, eliminating the need for fossil fuel combustion. This substitution achieves high process efficiency by directly heating the reactor tubes while avoiding CO2 emissions from fuel combustion.
Solution Approach 2:
The patent changes the energy source parameter from chemical energy (fossil fuels) to electrical energy. By using electrical heating elements with controllable power input, the system achieves precise temperature control and high heat flux delivery without the inefficiencies and emissions associated with combustion processes. The electrical energy can be sourced from renewable sources, further reducing harmful emissions.
2Object-generated harmful factors
If electrical heating is applied to industrial-scale chemical conversion processes, then CO2 production is reduced and process efficiency improves, but handling high temperature and heat flux requirements becomes challenging
Solution Approach 1:
The patent replaces combustion-based heating with electrical resistance heating elements that can deliver high heat flux directly to the reactor tubes. The electrical heating elements are designed with high power density capabilities, allowing them to meet the high temperature requirements of endothermic chemical reactions without the limitations of combustion systems.
Solution Approach 2:
The patent applies electrical heating elements directly to the reactor tubes, creating localized high heat flux zones where needed. This localized heating approach allows precise control of temperature profiles along the reactor length, ensuring that high temperature requirements are met at specific locations without overheating other areas. The heating elements can be strategically positioned to match the thermal demands of different reactor zones.
3Use of energy by moving object
If electrical heating elements are placed in direct contact with reactor tubes for efficient heat transfer, then heat transfer efficiency improves, but the heating elements are exposed to harsh chemical environments
Solution Approach 1:
The patent introduces a protective coating or refractory material layer as an intermediary between the electrical heating elements and the harsh chemical environment inside the reactor. This intermediary layer allows efficient thermal conduction from the heating elements to the reactor tube while protecting the heating elements from corrosive gases, coking, and other damaging conditions. The intermediary maintains thermal contact while providing environmental isolation.
4Reliability
If inspection ports are added to monitor reactor tubes during operation, then reliability improves, but device complexity increases
Solution Approach 1:
The patent incorporates inspection ports that enable visual or instrumental monitoring of the reactor tubes during operation. This feedback mechanism allows operators to detect issues such as tube degradation, coking, or thermal anomalies in real-time, enabling preventive maintenance and avoiding unplanned shutdowns. The inspection ports provide continuous information about the reactor tube condition without requiring complex sensor systems or automated monitoring infrastructure.
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 configuration achieves high process efficiencies, reduces CO2 production, and enables cost-effective integration of renewable power into industrial-scale chemical conversion reactions, offering a scalable and sustainable alternative to conventional fossil fuel-based heating technologies.
Implementation Method 1
at least one electrical radiative heating element suitable for heating the reactor tube to high temperatures
Implementation Method 2
electrical radiative heating element...allow for efficient heat transfer by radiation, convection, and conduction
Implementation Method 3
allow for efficient heat transfer by radiation, convection, and conduction
Implementation Method 4
allow for efficient heat transfer by radiation, convection, and conduction
Data Source
AI summary
The invention relates to a reactor configuration comprising an electrically heated furnace, with at least one reactor tube placed within the furnace and said reactor tube having an exit and entrance outside of the reactor furnace, and wherein said furnace is further provided withat least one electrical radiative heating element suitable for heating to high temperatures located inside said furnace in such a way that the heating element is in no direct contact with the reactor tube; and; anda number of inspection ports in the furnace wall such to be able to visually inspect the condition of the reactor tube on each opposite side of said reactor tube during operation, the total number of inspection ports being sufficient to inspect all reactor tubes present in the furnace at their full length and circumference; and wherein the heating duty of the furnace is at least 3 MW.