Non-Linear Channel Reactor Assembly for Solar Thermal Stress Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Reactor systems face issues with hot spots and thermal stress due to imperfections in solar concentrator optics, leading to reduced lifetime and increased costs, as well as inefficiencies in energy utilization in endothermic reactions like steam methane reforming.
Innovation Solution
The use of stacked reactor assemblies with non-linear fluid channels oriented in thermal contact, allowing for thermal spreading and energy recuperation, which reduces hot spots and thermal stress, and enhances energy efficiency by utilizing solar energy for endothermic reactions such as methane steam reforming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional steam methane reforming is used with solar concentrators, then hydrogen production is achieved, but hot spots and thermal stress occur due to imperfections in solar concentrator optics, reducing reactor lifetime
Solution Approach 1:
The reactor is divided into multiple channels arranged in a serpentine pattern, segmenting the thermal load across multiple pathways. This segmentation prevents concentration of thermal stress in a single location, thereby reducing hot spots and extending reactor lifetime while maintaining hydrogen production capacity
Solution Approach 2:
The serpentine (curved) channel configuration distributes thermal energy more evenly throughout the reactor volume compared to straight linear channels. The curved pathways lengthen the heat transfer path and promote more uniform thermal spreading, reducing thermal stress concentrations and improving reactor reliability under solar concentrator operation
2Ease of manufacture
If linear fluid channels are used, then simple manufacturing is achieved, but inefficient energy utilization occurs in endothermic reactions
Solution Approach 1:
The serpentine channel configuration optimizes energy utilization by extending the fluid pathway length within the same footprint, increasing thermal contact area and residence time for endothermic reactions. This curved geometry enhances heat transfer efficiency and energy utilization while remaining manufacturable using standard fabrication techniques
3Device complexity
If solar concentrator optics with imperfections are used, then cost reduction is achieved, but hot spots and thermal stress increase, reducing reactor performance
Solution Approach 1:
The serpentine channel configuration converts the harmful effect of non-uniform solar flux distribution (hot spots) into a beneficial thermal spreading mechanism. The curved pathways redirect and distribute concentrated thermal energy across multiple channel segments, transforming localized thermal stress into uniform heat distribution that enhances reaction efficiency without requiring perfect optics
Solution Approach 2:
The reactor geometry parameters (serpentine path length, channel spacing, curvature radius) are optimized to match the non-uniform solar flux profile. By adjusting these parameters, the system adapts to imperfect concentrator optics, distributing thermal energy evenly across the reactor volume and eliminating hot spots while maintaining high temperature conditions necessary for endothermic reactions
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 achieves improved reactor lifetime, reduced operating and capital costs, and higher energy efficiency by effectively distributing thermal energy across a larger reactor area, enabling up to 85% thermal-to-chemical energy conversion efficiency and maintaining high performance under high flux conditions.
Implementation Method 1
a first set of fluid channels and a second set of fluid channels oriented in thermal contact with the first set of fluid channels
Implementation Method 2
Solar thermochemical production of hydrogen from natural gas or other sources of methane can have the advantage of greater overall energy efficiency and reduced carbon emissions
Implementation Method 3
heat for the channels can be provided from a variety of sources, including electrical heating, exothermic chemical processes, and/or solar energy. Reactors and/or methods can provide a high temperature endothermic reaction such as methane steam reforming
Data Source
AI summary
Reactors are provided that can include a first set of fluid channels and a second set of fluid channels oriented in thermal contact with the first set of fluid channels. The reactor assemblies can also provide where the channels of either one or both of the first of the set of fluid channels are non-linear. Other implementations provide for at least one of the first set of fluid channels being in thermal contact with a plurality of other channels of the second set of fluid channels. Reactor assemblies are also provided that can include a first set of fluid channels defining at least one non-linear channel having a positive function, and a second set of fluid channels defining at least another non-linear channel having a negative function in relation to the positive function of the one non-linear channel of the first set of fluid channels. Processes for distributing energy across a reactor are provided. The processes can include transporting reactants via a first set of fluid channels to a second set of fluid channels, and thermally engaging at least one of the first set of fluid channels with at least two of the second set of fluid channels.