Electromagnetic Induction Pyrolysis Reactor for Precise Temperature Control
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Solution Overview
Problem
Current pyrolysis methods face challenges in precise temperature control and scalability, particularly in industrial processes, with combustion pyrolysis limited by temperature control and microwave heating restricted by magnetron power and high costs, while electromagnetic induction heating lacks reported applications in combination with spray technology.
Innovation Solution
A novel device integrating electromagnetic induction heating with spray technology, comprising a feeding pump, flow meter, atomizer, pyrolysis reactor, electromagnetic coils, temperature sensor, and condenser, allowing for precise temperature control and efficient heat transfer, enabling rapid and uniform pyrolysis of feedstocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If combustion pyrolysis is used to provide heat for the cracking furnace, then high temperature environment can be formed, but precise temperature control cannot be achieved and the method is only suitable for waste liquid treatment
Solution Approach 1:
The patent replaces the mechanical combustion heating system with an electromagnetic induction heating system. The induction heating coil generates electromagnetic fields that directly induce eddy currents in the feedstock, enabling rapid and precise temperature control without the thermal inertia and control difficulties associated with combustion systems.
Solution Approach 2:
The patent changes the heating method from combustion to electromagnetic induction, which fundamentally alters the heating parameters including heating rate, temperature distribution uniformity, and response time. This enables precise temperature control while expanding application scope to valuable chemical production.
2Productivity
If microwave heating is used for pyrolysis of methyl ricinoleate, then pyrolysis can be achieved, but processing capacity is limited by magnetron power and scale-up is difficult
Solution Approach 1:
The patent replaces the microwave heating system with an electromagnetic induction heating system. The induction heating coil can be scaled in size and power capacity more easily than magnetrons, allowing for increased processing capacity without proportionally increasing device complexity.
3Ease of manufacture
If microwave heating is used for pyrolysis, then pyrolysis reactions can be performed, but microwave absorbing materials are needed as heating medium which increases cost
Solution Approach 1:
The patent replaces microwave heating with electromagnetic induction heating, eliminating the need for microwave-absorbing materials. The induction heating coil directly induces eddy currents in the conductive feedstock or heating medium, providing efficient heating without additional material costs.
4Speed
If spray technology is applied in pyrolysis reactions, then rapid heating and pyrolysis can be realized, but few reports on application of electromagnetic induction heating coupled with spray technology were found
Solution Approach 1:
The patent merges spray technology with electromagnetic induction heating in a unified system. The spray device atomizes the feedstock into fine droplets that are rapidly heated by the induction heating coil, combining the advantages of both technologies for efficient and versatile pyrolysis processing.
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 combination achieves fast heating, high thermal efficiency, and improved yield of target products by eliminating contact resistance and allowing for scalable and efficient pyrolysis reactions, doubling the yield of undecylenic acid compared to conventional methods.
Implementation Method 1
Electromagnetic induction heating is widely used due to its excellent heating performance (Chinese patents CN 103561491A, CN 105025604A, CN 107477844A and CN 107339796A). This heating method has the advantages of fast heating start, high thermal efficiency and good heating uniformity.
Implementation Method 2
For the spray technology, liquid feedstock is broken into uniform and fine droplets, and efficient heat transfer can be achieved. The spray technology is widely used in cooling, combustion and pyrolysis (Chinese patents CN 102951616A, CN 103740904A, CN 104061797A, CN 106744716A and CN 106987691A). The main advantage of heat transfer using spray technology lies in no contact resistance between the atomized material and the heat transfer surface, and thus the efficient and rapid heat transfer is achieved for the atomized material.
Implementation Method 3
a feeding pump (1), a flow meter (2), an atomizer (3), a pyrolysis reactor (4), electromagnetic coils (5), an electromagnetic induction heating power (6), a temperature sensor (7), a temperature controller (8), a condenser (9) and a product tank (10)
Data Source
AI summary
A device for pyrolysis reactions includes a feeding pump, a flow meter, an atomizer, a pyrolysis reactor, electromagnetic coils, an electromagnetic induction heating power, a temperature sensor, a temperature controller, a condenser and a product tank. The feeding pump is connected with the flow meter which is connected to the inlet of the atomizer in the pyrolysis reactor. There is a port at the bottom of the pyrolysis reactor, with the port at the top of the pyrolysis reactor connected with the condenser. The condenser is connected with the product tank. The external wall of the pyrolysis reactor is surrounded by electromagnetic coils which are connected with the electromagnetic induction heating power. The temperature sensor is placed between the pyrolysis reactor and the coils, which is connected with the temperature controller. The contact resistance between the atomized material and the hot surface can be.