Multiphase Reactor Tubes for High-Current Chemical Heating
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Solution Overview
Problem
Conventional reactors used in chemical processes for producing synthesis gas, hydrogen, and olefins require high-current feeds and result in high carbon dioxide emissions, making them inefficient and costly, especially when using fossil energy carriers.
Innovation Solution
A reactor design utilizing multiphase alternating current with a thermally insulating reactor wall and electrically heatable reaction tubes, where each reaction tube is connected to only one phase, increasing the heated length and resistance, allowing for higher power input at constant current intensity and reducing the complexity and losses associated with high-current feeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the electrically conductive pipeline is connected to multiple phases of alternating current to form a star point circuit, then heat is generated according to electrical resistance, but the heated tube length and ohmic resistance are limited, requiring high current intensity and low voltage
Solution Approach 1:
The reactor is divided into multiple independent reaction tube groups, with each group connected to a separate phase of the alternating current. This segmentation allows each group to be heated independently, increasing the total heated length and ohmic resistance without requiring excessively high current intensity, thereby reducing the complexity of the power supply system.
2Power
If conventional fired reactors are used to produce synthesis gas and hydrogen, then heating is achieved through burning, but carbon dioxide emissions are high
Solution Approach 1:
The conventional thermal heating system based on combustion is replaced with an electrical heating system. Electrical energy is used to generate heat through resistive heating in the reaction tubes, eliminating the need for burning fossil fuels and thereby significantly reducing carbon dioxide emissions while maintaining the required heating capability for the chemical reactions.
3Power
If high current intensity is used to introduce required heating power into the pipeline, then heating power is sufficient, but mechanical and material complexity increases
Solution Approach 1:
The power supply system is segmented into multiple phases, with each phase serving a separate reaction tube group. This distribution reduces the current intensity required for each individual group, simplifying the mechanical and material requirements for the power supply system while maintaining sufficient heating power through the cumulative effect of multiple groups.
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 design enables more efficient heating with reduced power losses and lower carbon dioxide emissions, making the process more sustainable and cost-effective for endothermic chemical reactions.
Implementation Method 1
heat is generated according to the electrical resistance of the pipeline
Implementation Method 2
the ohmic resistance are limited
Implementation Method 3
a reactor vessel formed by a thermally insulating reactor wall
Data Source
AI summary
A reactor for carrying out a chemical reaction includes a reactor wall and at least one group of M reaction tubes, each of which has an electrically heatable heating section that extends between a first and a second removal region. Each heating section has a respective feed region in a region which extends over 20% to 80% of a heating length of the heating section and electrically conductive feed elements. Each group M is paired with the feed elements connected to the feed regions of the group, and different phases of the alternating current can be fed to different feed elements paired with a group. Each group is paired with M first and M second removal elements connected to the first or second removal regions of the group, respectively. Each group is paired with a first and a second star bridge.