Intermediate Heat Transfer Loop for Thermal Conversion
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Solution Overview
Problem
Industrial processes, particularly those using industrial furnaces, face significant challenges in reducing CO2 emissions due to high temperature requirements and inefficiencies in current catalysts and membrane reactors, making significant greenhouse gas reductions economically infeasible.
Innovation Solution
A novel process configuration utilizing multiple conversion and separation steps in series, combined with an intermediate heat transfer loop, leverages renewable heat sources like molten salt or metals from concentrated solar plants or nuclear reactors to achieve total conversion rates equal to or higher than current processes, while integrating heat transfer technology to optimize thermal efficiency and reduce steam production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple conversion and separation steps in series are implemented, then total conversion rate is improved, but device complexity increases
Solution Approach 1:
The process is divided into multiple conversion steps and separation steps arranged in series. Each step performs a specific function (methane conversion, water-gas shift, CO2 separation, hydrogen production) to progressively increase the total conversion rate from feedstock to final products, with unreacted materials being recycled through the system.
Solution Approach 2:
The system operates continuously with multiple trains running in parallel, where effluent from one train is recycled back through subsequent trains. This continuous circulation ensures that unreacted materials are repeatedly processed until complete conversion is achieved, maintaining steady-state operation while maximizing productivity.
2Use of energy by moving object
If intermediate heat transfer loop with multiple loops is used, then thermal efficiency is improved, but device complexity increases
Solution Approach 1:
An intermediate heat transfer fluid loop is introduced as a mediator between the solar receiver and the process equipment. This intermediate loop receives concentrated solar energy and distributes thermal energy to multiple process trains through heat exchangers, enabling efficient thermal coupling while providing operational flexibility and isolation between the solar field and process units.
Solution Approach 2:
The intermediate heat transfer loop serves multiple functions: it transfers thermal energy from the solar receiver to various process units, provides thermal storage capability, enables independent operation of different process trains, and facilitates heat recovery and redistribution throughout the system, making the overall system more versatile and efficient.
3Object-generated harmful factors
If renewable heat sources are utilized, then CO2 emissions are reduced, but manufacturing precision and process control become more difficult
Solution Approach 1:
The system utilizes variable parameters of renewable heat sources (temperature, heat flux, availability) by designing flexible process trains that can operate at different thermal conditions. The intermediate heat transfer loop allows decoupling of solar input variability from process requirements, enabling precise control of reaction conditions while maintaining low emissions through continuous operation and optimization.
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 continuous cyclical CO2 capture and hydrogen production with high purity, reducing CO2 emissions and operational costs by achieving higher conversion rates and thermal efficiency, making industrial processes more environmentally friendly and economically viable.
Implementation Method 1
circulating an intermediate heat transfer fluid through the housing and about the four or more discreet heat transfer devices; the intermediate heat transfer fluid is indirectly heated by the heated primary heat transfer fluid from both the first and second discreet heat transfer devices
Implementation Method 2
causing a thermal conversion of at least a part of the feed to produce a product, byproduct and possibly a portion of unreacted feed
Implementation Method 3
cooled to 440° C. (to obtain 95% conversion of the CO to CO2 in the Water Gas Shift (WGS) reaction)
Data Source
AI summary
Methods and systems for producing a thermally converted product stream (and optionally heat and power) from a high value heat source using a plurality of circulating loops comprising a primary heat transfer loop, several substantially not recirculated process heater, reactor or separator systems and an intermediate heat transfer loop that transfers heat from the high-temperature heat transfer loop to the several process heater, reactor or separator systems. The intermediate heat transfer loop is arranged to eliminate to the extent practical the shell and tube heat exchangers especially those heat exchangers that have a very large pressure difference between the tube side and shell side, to eliminate shell and tube, plate type, double pipe and similar heat exchangers that transfer heat directly from the primary heat transfer loop to the several process heater, reactor or separator systems with very high differential pressures and to maximize the use of heat transfer coils similar in design as are used in a heat recovery steam generator commonly used to transfer heat from gas turbine flue gas to steam or other power cycle fluids as part of a combined cycle power plant.