Integrated Heat Exchange System for Hydrogen Production
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Solution Overview
Problem
Current heat exchange systems in hydrogen and synthesis gas production processes are complex and costly, with inefficient heat recovery and transformation, particularly in catalytic partial oxidation and Water Gas Shift reactions, leading to high energy costs and equipment encumbrances.
Innovation Solution
A single central heat exchange system with immersed heat exchange surfaces in a fluid bath, facilitating natural circulation for both heating and cooling, transforming excess heat into steam for reuse, integrated within a single apparatus with distinct areas for heat transfer and vapour collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple separate heat exchange devices are used for heating and cooling different process flows, then heat exchange functionality is achieved, but device complexity and equipment costs increase
Solution Approach 1:
The patent combines multiple heat exchange surfaces (heating surfaces and cooling surfaces) into a single integrated apparatus containing a fluid bath. Different process flows are simultaneously heated and cooled within this single device through direct contact with the fluid bath, eliminating the need for multiple separate heat exchange devices and reducing overall system complexity.
Solution Approach 2:
The fluid bath serves multiple functions simultaneously: it acts as a heating medium for cold flows, a cooling medium for hot flows, and a heat transfer intermediary between different process streams. This multi-functional design allows one apparatus to perform what previously required multiple specialized devices.
2Device complexity
If traditional heat exchange equipment is used, then heat transfer is achieved, but equipment encumbrances and installation complexity increase
Solution Approach 1:
By integrating all heat exchange surfaces and the fluid bath into a single compact apparatus, the patent reduces equipment encumbrances and simplifies installation. The unified design eliminates the need for complex piping networks and multiple separate installations, thereby reducing installation risks and improving ease of operation.
3Productivity
If heat exchange surfaces are not completely immersed in fluid bath, then heat transfer efficiency is maintained, but natural circulation and thermal energy transformation are reduced
Solution Approach 1:
The patent utilizes phase transitions of the fluid bath (boiling and condensation) to transform excess thermal energy into vapour phase. Heat exchange surfaces completely immersed in the fluid bath facilitate efficient heat transfer that drives these phase transitions, converting waste heat into useful vapour while maintaining high heat exchange efficiency.
Solution Approach 2:
The system employs natural circulation driven by density differences created during phase transitions. The fluid bath automatically circulates heat without external pumping, with vapour rising and condensing to create continuous natural flow, reducing energy loss and maintaining efficiency through self-sustaining thermal convection.
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 solution simplifies heat exchange operations, enhances energy efficiency, reduces equipment costs, and allows for pre-assembled units with reduced installation risks, effectively optimizing thermal energy recovery and utilization in hydrogen and synthesis gas production processes.
Implementation Method 1
one or more heat exchange surface (6, 7, 8) yielding heat to the flows of cold material and one or more heat exchange surface (9, 10, 11) absorbing heat from the flows of hot material
Implementation Method 2
transforming the excess heat present in the system into steam
Implementation Method 3
a strong natural circulation is created in the fluid bath which allows heat exchange and balancing
Data Source
AI summary
The present invention relates to a heat exchange system comprising: - a single apparatus (N) having an area immersed in a fluid bath (N2) and a free space (N1) at the head in which a vapour phase is accumulated, - at least one interspace (P) open at both ends, situated inside said apparatus and completely immersed in the fluid bath, - one or more heat exchange surface (s) (6, 7, 8, 9, 10, 11), said system characterized in that it contains all the heat exchange surfaces in a single apparatus and said surfaces are completely immersed in the fluid bath and are fluidly connected to the hot and cold sources, external to said system, through flows of matter. At least one of the heat exchange surfaces (6, 7, 8) is situated inside the interspace and at least another surface (9, 10, 11) is situated in the space between said interspace and the walls of the apparatus.