Moving Bed Pyrolysis Reactor With PCM Heat Transfer Media

Solution Overview

Problem

Industrial hydrogen production through steam methane reforming is energy-intensive and produces significant carbon dioxide emissions, and existing separation methods are costly and inefficient, while high-temperature hydrocarbon pyrolysis reactors face challenges with carbon deposition and heat transfer limitations.

Innovation Solution

A moving bed reactor configuration using a heat transfer media with a phase change material (PCM) and a core/annulus design to manage high temperatures, reduce carbon deposition, and enhance heat transfer efficiency, combined with a shielding gas to prevent reactant contact with heating elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If steam methane reforming is used for hydrogen production, then hydrogen can be produced, but energy consumption is high and carbon dioxide emissions are significant

Engineering Contradiction:

Improveenergy consumptionVSAvoidcarbon dioxide emissions

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The patent changes the temperature parameter by using high-temperature pyrolysis (above 1000°C) instead of conventional steam methane reforming, enabling direct production of hydrogen and carbon without CO2 emissions. This parameter change fundamentally alters the chemical process to eliminate harmful emissions while maintaining hydrogen production.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the harmful effect of carbon deposition (coke formation) into a beneficial process by using the deposited carbon as a heat transfer medium. The carbon particles are circulated through the reactor, absorbing heat and transferring it to the hydrocarbon feedstock, thereby utilizing what would normally be waste into a useful heat transfer function.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If high-temperature hydrocarbon pyrolysis is used, then hydrogen yield improves, but carbon deposition and heat transfer limitations occur

Engineering Contradiction:

Improvehydrogen yieldVSAvoidcarbon deposition

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful effect of carbon deposition into a beneficial heat transfer mechanism. Carbon particles deposited during pyrolysis are collected and circulated as a heat transfer medium, absorbing heat from the reactor walls and transferring it to the hydrocarbon feedstock, thereby eliminating the harmful deposition effect while improving heat transfer efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent utilizes phase transitions of the carbon particles between solid and liquid states to facilitate heat transfer. The carbon particles undergo melting and solidification cycles, absorbing and releasing latent heat during these transitions, which enhances the overall heat transfer efficiency in the high-temperature pyrolysis process.

Inventive Principle:

Principle #36Phase transitions

3Power

If conventional heat transfer media are used, then heat transfer occurs, but heat transfer efficiency is limited at high temperatures

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidhigh temperature operation

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The patent converts the harmful effect of carbon deposition into a beneficial heat transfer mechanism. Carbon particles deposited during pyrolysis are collected and circulated as a heat transfer medium, absorbing heat from the reactor walls and transferring it to the hydrocarbon feedstock, thereby eliminating the harmful deposition effect while improving heat transfer efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent utilizes phase transitions of the carbon particles between solid and liquid states to facilitate heat transfer. The carbon particles undergo melting and solidification cycles, absorbing and releasing latent heat during these transitions, which enhances the overall heat transfer efficiency in the high-temperature pyrolysis process.

Inventive Principle:

Principle #36Phase transitions

4Productivity

If pressure swing adsorption is used for separation, then hydrogen and methane can be separated, but the process is costly and energy-intensive

Engineering Contradiction:

Improveseparation efficiencyVSAvoidenergy intensity

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent converts the harmful effect of carbon deposition into a beneficial heat transfer mechanism. Carbon particles deposited during pyrolysis are collected and circulated as a heat transfer medium, absorbing heat from the reactor walls and transferring it to the hydrocarbon feedstock, thereby eliminating the harmful deposition effect while improving heat transfer efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

The PCM media allows for high-temperature heat storage and transfer, reducing energy consumption and carbon emissions, while the core/annulus design improves heat recovery and gas flow control, enhancing hydrogen yield and reducing operational costs.

Implementation Method 1

The discontinuous phase has a melting point selected to be within a reaction temperature range

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

The matrix material has a higher melting point than the discontinuous phase

Methodology Applied

Scientific EffectLatent heat: Latent Heat

Implementation Method 3

heat transfer media with a phase change material (PCM)

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

moving bed reactor configuration

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12478939B2Moving bed reactor for hydrocarbon pyrolysis

Publication Date: 2025.11.25 CZERO INC

AI summary

A heat transfer media comprises a particle. The particle comprises a discontinuous phase and a matrix material. The discontinuous phase is disposed within the matrix material, and the matrix material has a higher melting point than the discontinuous phase. The discontinuous phase has a melting point selected to be within a reaction temperature range.