Electrical Coupler With Fluid Passages for Direct Reactor Heating
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Solution Overview
Problem
Traditional catalytic reactor systems suffer from poor heat utilization and high CO2 emissions due to external combustion heating, necessitating more efficient and economic heating methods.
Innovation Solution
The use of electrical couplers, such as electrodes, that provide electrical energy directly to the catalyst, allowing for resistive heating closely coupled to the catalytic surface, thereby improving heat transfer efficiency and reducing CO2 emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If external combustion heating is used, then heat generation is decoupled from the catalytic surface, but heat transfer efficiency deteriorates and CO2 emissions increase
Solution Approach 1:
The patent merges the heat generation function with the catalytic surface by using resistive heating elements directly integrated into the reactor walls or as internal coils, eliminating the need for external combustion. This direct integration ensures that heat is generated exactly where it is needed, maximizing heat transfer efficiency while avoiding CO2 emissions from external fuel combustion.
Solution Approach 2:
The patent replaces the mechanical/chemical combustion heating system with an electrical resistive heating system. By substituting electrical energy for chemical combustion, the system achieves direct heat generation at the catalytic surface without the intermediate steps of external combustion and heat transfer, thereby eliminating CO2 emissions and improving thermal efficiency.
2Loss of energy
If electrical couplers are used for resistive heating, then heat transfer efficiency improves, but device complexity increases
Solution Approach 1:
The electrical couplers are designed to serve multiple functions simultaneously: they provide electrical connectivity for resistive heating, act as structural support for the catalytic elements, and facilitate fluid distribution. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving improved heat transfer efficiency.
Solution Approach 2:
The patent implements a nested structure where electrical couplers are integrated within the reactor wall structure or positioned concentrically with the catalytic elements. This nesting approach allows the electrical heating system to be embedded within the existing reactor architecture, minimizing additional complexity while maximizing heat transfer efficiency through direct coupling.
3Object-generated harmful factors
If electrical couplers are used for direct heating, then CO2 emissions are reduced, but reliability under corrosive conditions may deteriorate
Solution Approach 1:
The electrical couplers are constructed from composite materials that combine corrosion-resistant alloys with electrically conductive properties. This composite structure allows the couplers to withstand the corrosive reaction environment while maintaining their electrical functionality for resistive heating, thereby reducing CO2 emissions without compromising reliability.
Solution Approach 2:
The patent employs inert or protective atmospheres within the reactor to minimize corrosion of the electrical couplers. By controlling the chemical environment to be less aggressive toward the coupler materials, the system achieves reduced CO2 emissions from external combustion while maintaining the reliability and longevity of the electrical heating components.
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 enhances heat transfer efficiency, reduces CO2 emissions, and maintains reactor performance under corrosive conditions by using electrical couplers that are stable and fluidically permeable, minimizing degradation.
Implementation Method 1
The catalytic element is resistively heated to a temperature greater than about 1000° C. by an electrical current provided between the first electrode and the second electrode
Implementation Method 2
at least one opening extending from the first end to the second end, the at least one opening configured to allow a fluid to flow through the electrical coupler
Data Source
AI summary
An electrical coupler for a resistively heated reactor system including an electrical conductor having a first end and a second end, defining a thickness therebetween, each of the first end and the second end having a first interface in the first end and a second interface in the second end and, at least one opening extending from the first end to the second end, the at least one opening configured to allow a fluid to flow through the electrical coupler.