Electrically Heated Moving-Bed Reactor With Carbon Removal
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Solution Overview
Problem
Existing endothermic reaction processes, such as steam reformation and cracking, face issues with carbon deposition leading to reduced flowability and clogging of inert solid particles, limiting their economic viability and requiring fossil fuel heating, which also contributes to CO₂ emissions.
Innovation Solution
A reactor design with a moving bed of solid particles heated by Joule heat, using electrodes to transfer heat to feed gas for reaction, and integrating heat transfer zones to optimize efficiency and eliminate fossil fuel use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If inert solid particles are conveyed as bulk material through the reaction zone for endothermic reactions, then the process can eliminate fossil fuel heating and reduce CO2 emissions, but carbon deposition leads to reduced flowability and clogging of the solid particles
Solution Approach 1:
The patent extracts and removes carbon deposits from the solid particles continuously during operation. A removal unit is provided that separates and removes carbon from the solid particles, preventing accumulation that would cause clogging and maintain flowability while enabling continuous operation without fossil fuel heating
Solution Approach 2:
The patent implements continuous carbon removal during the reaction process. The solid particles are continuously circulated through the reaction zone and the carbon removal unit operates continuously to maintain particle flowability, ensuring uninterrupted endothermic reaction without periodic shutdowns for decoking
2Object-generated harmful factors
If electric voltage is applied to heat solid particles for endothermic reactions, then fossil fuel heating is eliminated, but carbon deposition on particles causes clogging after prolonged operation
Solution Approach 1:
The patent introduces an intermediary carbon removal unit between the reaction zone and particle circulation. This unit acts as a mediator that continuously eliminates carbon deposits from particles, allowing the electrically heated reaction process to operate continuously without the clogging that would otherwise limit operational duration
Solution Approach 2:
The patent discards carbon deposits removed from the solid particles during continuous operation. The carbon is separated in the removal unit and discarded, while the cleaned particles are returned to circulation, enabling prolonged continuous operation without accumulation of harmful carbon deposits
3Loss of energy
If solid particles are used for heat transfer in the reaction zone, then heat integration efficiency is improved, but carbon deposition reduces particle flowability and causes clogging
Solution Approach 1:
The patent continuously extracts carbon deposits from the solid particles that serve as heat transfer media. By removing carbon that would impede flow, the particles maintain their flowability and heat transfer efficiency, ensuring sustained high productivity in the reaction zone
Solution Approach 2:
The patent implements a feedback loop where solid particles are continuously monitored for carbon deposition and circulated back through the removal unit when needed. This feedback mechanism maintains optimal particle flowability and heat transfer performance, preventing productivity decline from clogging
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 reactor achieves efficient heat integration, reduces CO₂ emissions, and prevents clogging by maintaining solid particle flowability, enabling high process efficiency and reduced operational costs.
Implementation Method 1
the reactor is designed to heat the solid particles in the reaction zone (e.g. by generating an electric current in the solid particles, i.e., by generating Joule heat in the solid particles)
Implementation Method 2
the feed gas in the reaction zone can be heated to a reaction temperature by transferring heat from the solid particles to the feed gas
Implementation Method 3
a first heat integration zone in which heat from the product gas generated in the reaction zone can be transferred to solid particles of the reactor bed to be introduced into the reaction zone
Implementation Method 4
a second heat integration zone in which heat from solid particles of the reactor bed coming from the reaction zone can be transferred to the feed gas for preheating
Data Source
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AI summary
The invention relates to a reactor (1) for carrying out an endothermic reaction, in particular a high-temperature reaction, in which a product gas (P) is obtained from a feed gas (E), wherein the reactor (1) surrounds a reactor interior (10), wherein the reactor (1) is configured to provide a plurality of solid particles (F) in a reaction zone (12) of the reactor interior (10) having a reactor bed (120), wherein the reactor (1) is further configured to feed the feed gas (E) into the reaction zone (12), wherein the reactor (1) is designed to heat the solid particles (F) in the reaction zone (12) so that the feed gas (E) in the reaction zone (12) can be heated to a reaction temperature by transferring heat from the solid particles (F) to the feed gas (E) in order to participate as a reactant in the endothermic reaction to produce the product gas (P).and wherein the reactor interior (10) further comprises a first heat integration zone (11) in which heat from the product gas (P) generated in the reaction zone (12) can be transferred to solid particles (F) of the reactor bed (120) to be introduced into the reaction zone (12), and wherein the reactor interior (10) further comprises a second heat integration zone (13) in which heat from solid particles (F) of the reactor bed (120) coming from the reaction zone (12) can be transferred to the feed gas (E) for preheating. The invention further relates to a process in which a reactor (1) according to the invention is used.