Micro Channel Reactor Heat Exchange Integration
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Solution Overview
Problem
Conventional water-gas shift reactor systems face challenges in effectively removing heat generated during exothermic reactions, leading to reduced catalyst lifespan and decreased shift ratios due to non-uniform temperature distribution and the need for complex heat-exchange systems, which increases system size and instability.
Innovation Solution
A micro channel reactor system with integrated reaction and heat-exchanging channel plate assemblies, where reaction gas and cooling fluid are introduced separately through multiple channel units, with intermediate plates supplying reactants and cooling fluids, and end plates managing gas and fluid discharge, allowing for efficient heat exchange without additional cooling means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a fixed-bed reactor is used for water-gas shift reaction, then the reaction can be performed, but heat generated during exothermic reaction cannot be removed effectively, leading to non-uniform temperature distribution
Solution Approach 1:
The patent combines the reaction channel plate assembly and heat-exchanging channel plate assembly into a single integrated micro channel reactor system. The reaction channels and heat exchange channels are merged at the micro-scale, allowing simultaneous reaction and heat removal functions within the same structural framework, thereby achieving uniform temperature distribution while effectively removing heat.
Solution Approach 2:
The patent transitions from a conventional fixed-bed reactor structure to a micro channel plate structure with multiple dimensions. The reaction gas flows through reaction channels while cooling fluid flows through adjacent heat exchange channels, creating a multi-dimensional heat transfer pathway that enhances heat removal efficiency and temperature uniformity.
2Temperature
If separate high temperature and low temperature water-gas shift reaction systems are provided, then appropriate temperature control for each stage can be achieved, but the overall system size increases and complexity increases
Solution Approach 1:
The patent segments the reactor into multiple channel units stacked together, with each unit containing both reaction channels and heat exchange channels. This segmentation allows different regions to operate at different temperatures while maintaining a unified, compact structure, avoiding the need for completely separate high-temperature and low-temperature systems.
Solution Approach 2:
The micro channel reactor system performs multiple functions within a single integrated structure: it conducts both high-temperature and low-temperature water-gas shift reactions, provides heat exchange, and maintains temperature control all in one device. The same basic structural unit (channel plate assembly with heat exchange) serves multiple purposes across different temperature zones.
3Temperature
If separate high temperature and low temperature water-gas shift reaction systems are provided with sophisticated temperature controlling devices, then appropriate temperature can be maintained, but the system size increases
Solution Approach 1:
The patent merges the reaction vessels and heat exchange systems into a single integrated micro channel reactor. The reaction channels and heat exchange channels are combined at the micro-scale, eliminating the need for separate temperature controlling devices and reducing overall system volume while maintaining effective temperature control.
Solution Approach 2:
The patent uses micro-scale channel dimensions to achieve efficient heat transfer and temperature control without requiring large-volume external temperature controlling devices. The micro channel structure provides a high surface-area-to-volume ratio that enables effective heat exchange within a compact footprint.
4Duration of action of stationary object
If conventional fixed-bed reactor is used, then the reaction can be performed, but catalyst lifespan is reduced due to inability to remove heat completely
Solution Approach 1:
The patent combines catalyst-coated reaction channels with adjacent heat exchange channels in a unified micro channel structure. This integration allows continuous heat removal during the reaction process, preventing catalyst overheating and extending catalyst lifespan while maintaining complete heat removal capability.
5Productivity
If conventional fixed-bed reactor is used, then the reaction can be performed, but shift ratio is decreased due to non-uniform temperature distribution
Solution Approach 1:
The patent merges reaction and heat exchange functions in a unified micro channel structure with catalyst coating. This integration ensures uniform temperature distribution across the catalyst bed by continuously removing heat at the source, thereby maximizing the water-gas shift reaction efficiency and shift ratio.
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 configuration enhances thermal efficiency by directly exchanging heat between reaction and heat-exchanging channel plate assemblies, reducing system size and improving heat control, thereby extending catalyst life and maintaining reaction efficiency.
Implementation Method 1
a water-gas shift reaction process... CO+H2O═CO2+H2 ΔH=−41.1 kJ/mol
Implementation Method 2
heat generated when the water-gas shift reaction which is the exothermic reaction is performed
Implementation Method 3
a heat-exchanging channel plate assembly in which heat is exchanged
Implementation Method 4
heat generated when the water-gas shift reaction which is the exothermic reaction is performed
Implementation Method 5
cooling fluid are introduced separately through multiple channel units
Data Source
AI summary
The present invention discloses to a channel reactor system having a first channel plate assembly in which an exothermic reaction is performed and a second channel plate assembly provided for heat-exchanging and constituted integrally with the first channel plate assembly so as to remove effectively heat, the channel reactor system comprising at least two channel units into which reaction gas and cooling fluid are separately introduced, each channel unit comprising a reaction channel plate assembly into which reaction gas is introduced and a heat-exchanging channel plate assembly into which cooling fluid is introduced; and at least one intermediate plate disposed between the upper and lower channel units, the intermediate plate supplying reaction gas and cooling fluid inflowed from the upper channel unit with new reactant and cooling fluid and supplying reaction gas and cooling fluid to the reaction channel plate assembly and the heat-exchanging channel plate assembly of the lower channel unit, respectively.