Electrically Heated Reactor Tubes for Steam Reforming

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Solution Overview

Problem

Current methods for producing 'green' hydrogen, such as electrolysis, are costly, and there is a need for an efficient and environmentally friendly approach to produce synthesis gas and hydrogen using steam reforming of hydrocarbons like methane.

Innovation Solution

A furnace design that incorporates both combustion fuel heating and direct electrical heating of reactor tubes using a multi-phase alternating voltage system, allowing for the use of surplus or renewable electrical energy to reduce fuel consumption and enhance the steam reforming process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If electrolysis is used to produce green hydrogen, then environmental friendliness is improved, but production cost increases

Engineering Contradiction:

Improveenvironmental impactVSAvoidproduction cost

Core Design Contradiction:

Object-affected harmful factorsVSQuantity of substance

Solution Approach 1:

The patent introduces an intermediary system - a furnace with electrically heated reactor tubes - that bridges between conventional combustion-based steam reforming and fully electrical electrolysis. This intermediary approach allows steam reforming to be performed with reduced direct combustion by using electrical heating assistance, thereby lowering carbon emissions while avoiding the high costs of pure electrolysis.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Use of energy by moving object

If combustion fuel is used to heat reactor tubes, then heating efficiency is improved, but fuel consumption and environmental impact increase

Engineering Contradiction:

Improveheating efficiencyVSAvoidfuel consumption

Core Design Contradiction:

Use of energy by moving objectVSLoss of substance

Solution Approach 1:

The patent replaces part of the combustion-based heating system with an electrical heating system. Instead of relying solely on combustion fuel to heat the reactor tubes, electrical energy is introduced as an alternative heating source through voltage sources connected to the reactor tubes, thereby substituting mechanical/chemical energy conversion with direct electrical energy conversion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the energy input parameters of the steam reforming system by introducing electrical voltage and current as additional or alternative heating parameters. This allows flexible adjustment of heating intensity through electrical control, enabling optimization of fuel consumption while maintaining required reaction temperatures.

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If electrical heating is added to reactor tubes, then fuel consumption is reduced, but device complexity increases

Engineering Contradiction:

Improvefuel consumptionVSAvoidsystem complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The reactor tubes are designed with multi-functionality, serving both as reaction vessels and as electrical heating elements. The same reactor tubes that contain the catalyst and facilitate steam reforming also function as conductors for electrical heating, eliminating the need for separate heating devices and reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the heating function into the reactor tubes themselves by making the tubes electrically conductive or by providing electrical connections directly to them. This combines the structural component (reactor tube) with the heating function, simplifying the system architecture compared to adding separate external heating devices.

Inventive Principle:

Principle #5Merging (Combining)

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 approach enables the efficient production of synthesis gas and hydrogen by reducing combustion fuel usage, leveraging surplus electrical energy, and maintaining the effectiveness of established steam reforming technology while minimizing environmental impact.

Implementation Method 1

at least one voltage source which is connected to the plurality of reactor tubes in such a manner that in each case an electric current which heats the reactor tubes to heat the feedstock is generable in the reactor tubes

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

at least one burner which is configured to combust a combustion fuel in the combustion chamber to heat the reactor tubes

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 3

reactor tubes arranged in the combustion chamber for accommodating a catalyst and for passing the feedstock through the reactor tubes

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9908091B2Furnace with reactor tubes heatable electrically and by means of combustion fuel for steam reforming a feedstock containing hydrocarbon

Publication Date: 2018.03.06 LINDE AG

AI summary

A furnace for steam reforming a feed stream containing hydrocarbon, preferably methane, having: a combustion chamber, a plurality of reactor tubes arranged in the combustion chamber for accommodating a catalyst and for passing the feed stream through the reactor tubes, and at least one burner which is configured to burn a combustion fuel in the combustion chamber to heat the reactor tubes. In addition at least one voltage source is provided which is connected to the plurality of reactor tubes in such a manner that in each case an electric current which heats the reactor tubes to heat the feedstock is generable in the reactor tubes.