Multiphase Reaction Tube Heating for Higher Power Reactor Design
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Solution Overview
Problem
Current chemical reactors used in processes like steam cracking and steam reforming require high-current, low-voltage power supplies for heating, leading to mechanically and material-technically complex setups due to limited heated tube length and resistance, which is inefficient and costly, especially for producing syngas and hydrogen with reduced carbon emissions.
Innovation Solution
Connecting each reaction tube to only one phase and establishing phase equalization across multiple tubes increases the heated length and resistance, allowing for higher power input at constant current by increasing voltage, reducing the need for complex high-current supplies and power losses, while using thermally insulating reactor walls and electrically conductive materials like heat-resistant steel alloys for efficient heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the reaction tube is connected to multiple phases of alternating current, then the heated length and resistance are limited, but this requires high current and low voltage power supply which is mechanically and materially complex
Solution Approach 1:
The reaction tube is divided into multiple heating sections, each connected to a different phase of the alternating current. This segmentation allows each section to be heated independently by its respective phase, enabling the use of higher voltage and lower current while achieving the required total heating power.
Solution Approach 2:
The patent transitions from a single-phase high-current approach to a multi-phase distributed approach, adding the dimension of phase distribution across multiple heating sections. This dimensional change allows power delivery through voltage rather than current, simplifying the power supply system.
2Power
If high current is used to deliver required heating power with limited heated pipe length, then the heating power requirement is met, but mechanically and materially complex high-current power supplies are required
Solution Approach 1:
The heating system is segmented into multiple sections connected to different phases, distributing the power delivery across multiple lower-current channels. This makes the system easier to operate by using standard voltage levels rather than requiring specialized high-current equipment.
3Power
If the heated pipe length is increased to reduce resistance, then more power can be input at constant current, but the reactor vessel size and thermal insulation requirements increase
Solution Approach 1:
Instead of increasing the total heated length in a single continuous section, the patent segments the heating into multiple sections distributed along the reaction tube. Each section is heated by a different phase, achieving the required total power input without requiring a single long heated section that would increase reactor vessel volume.
4Power
If multiple high-current feeds are used to heat multiple reaction tubes, then each tube can be heated independently, but the number of feeds and associated power losses increase
Solution Approach 1:
The patent merges the power delivery function by connecting multiple reaction tubes to phases of a single alternating current source. The star bridge combines the neutral points of multiple tubes, allowing power to be delivered through fewer feeds while distributing heating across multiple tubes, thereby reducing power losses in the feed lines.
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 enables more efficient heating with reduced thermal losses and lower material requirements, allowing for higher heat output with fewer high-current feeds, thus addressing the inefficiencies and costs associated with traditional heating methods while enabling lower carbon emissions.
Implementation Method 1
each of which has an electrically heated heating section extending with a respective heating length between a first and a second downstream section of the respective reaction tube
Implementation Method 2
heat is generated according to the electrical resistance of the pipeline
Implementation Method 3
a reactor for carrying out a chemical reaction in a process fluid using multiphase alternating current to heat the process fluid
Data Source
Figure 1
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Figure 3
AI summary
A reactor is provided for carrying out a chemical reaction in a process fluid using M-phase alternating current to heat the process fluid. The reactor comprises a reactor wall; at least one group with M reaction tubes, each of which has an electrically heated heating section extending between a first and a second discharge area with a respective heating length, the heating sections each having a feed-in area in a region extending from 20% to 80% of their heating length; electrically conductive feed-in elements, each group having feed-in elements connected to the feed-in areas of the group, wherein different phases of the alternating current can be fed into different feed-in elements assigned to a group; electrically conductive first and second discharge elements, each group having the first and second discharge elements connected to the feed-in areas of the group, respectively.M first and M second pickup elements are assigned to the second pickup areas of the group; and at least one first and at least one second star bridge, wherein each group is assigned to a first and a second star bridge, wherein for each group the first pickup elements assigned to the group are connected to the first star bridge to which the group is assigned, and the second pickup elements assigned to the group are connected to the second star bridge to which the group is assigned.