Externally Heated Coil for Controlled Hydrocarbon Cracking
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Solution Overview
Problem
Conventional hydrocarbon cracking processes face challenges in achieving fine temperature control and are associated with high carbon footprints due to fuel combustion, which can lead to greenhouse gas emissions and difficulties in managing carbon-based fouling.
Innovation Solution
An apparatus and method for hydrocarbon cracking using an external heating component, such as an electrical resistor or combustion chamber, to provide controlled heat to the reactor, combined with a quench exchanger for cooling, to optimize temperature distribution and reduce fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is generated by combustion of fuel in a gas-fired furnace, then the hydrocarbon cracking process can achieve high temperature, but it negatively impacts the carbon footprint and contributes to greenhouse gas emissions
Solution Approach 1:
The patent replaces the chemical combustion system with an electrical heating system. Specifically, it uses induction heating coils or resistance heating elements to generate heat electrically rather than through fuel combustion, thereby eliminating greenhouse gas emissions while maintaining the required high cracking temperatures
Solution Approach 2:
The patent changes the energy source parameter from chemical energy (fuel combustion) to electrical energy (induction or resistance heating). This parameter change allows the system to achieve the same thermal effect without the harmful byproducts of combustion
2Temperature
If heat is generated by fuel combustion, then the cracking process can reach desired temperature, but it is difficult to achieve fine temperature control across the length of a cracking reactor
Solution Approach 1:
The patent divides the heating system into multiple independent heating zones along the reactor length. Each zone can be controlled separately with independent heating elements, allowing precise temperature control and uniform temperature distribution across different sections of the reactor
Solution Approach 2:
The patent implements dynamic control of heating parameters along the reactor length, allowing each heating zone to independently adjust its temperature output in real-time based on process requirements, achieving fine temperature control and uniform distribution
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
The solution achieves uniform or tailored axial heating, reducing reactor temperature, minimizing fouling, and enhancing the selectivity and yield of preferred products, while lowering the carbon footprint and extending the reactor's service life.
Implementation Method 1
The heating component can include an electrical resistor that is configured to produce the heat provided to the external surface of the reactor in response to receiving electrical power
Implementation Method 2
The quench exchanger can be configured to receive a cooling fluid and transfer heat from the reactor to the cooling fluid
Data Source
AI summary
An apparatus for hydrocarbon cracking includes a reactor and a heating component. The reactor has an interior cavity configured to receive a feed stream. The feed stream includes a hydrocarbon. The heating component surrounds the reactor. The heating component is configured to provide heat to an external surface of the reactor to crack the hydrocarbon and produce a product stream. The product stream includes a C2-C4 alkene, syngas, or a combination thereof. The reactor is configured to discharge the product stream. The heating component can include an electrical resistor, a combustion chamber, or both.