Moving Packed Bed Reactor Heating for Lower-Cost Pyrolysis
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Solution Overview
Problem
Conventional hydrocarbon pyrolysis systems operating at high temperatures face challenges in recovering energy efficiently, leading to high costs that make them economically unviable.
Innovation Solution
Implementing a moving packed bed processing plant with medium temperature heating and superheating sections to optimize energy use, utilizing a reactor with a particle preheating, high temperature, and decomposition and reaction sections, along with energy recovery systems to achieve efficient gas and solid product production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrocarbon pyrolysis systems operate at high temperatures (1,000-2,000 Celsius), then the decomposition and reaction efficiency is improved, but the energy cost increases and energy recovery becomes difficult
Solution Approach 1:
The reactor is divided into three distinct sections: a particle preheating section, a high temperature section, and a decomposition and reaction section. This segmentation allows each section to operate at optimized temperatures for its specific function, with the preheating section recovering energy from outgoing particles to preheat incoming particles, thereby reducing overall energy costs while maintaining high reaction efficiency in the decomposition section.
2Productivity
If conventional hydrocarbon pyrolysis systems operate at high temperatures (1,000-2,000 Celsius), then the decomposition and reaction efficiency is improved, but the economic viability deteriorates
Solution Approach 1:
The system recovers energy from particles exiting the decomposition and reaction section by using them as a heat source in the particle preheating section. This energy recovery mechanism reduces the external energy input required, thereby improving economic viability while maintaining high decomposition and reaction efficiency in the high temperature section.
3Use of energy by moving object
If a moving packed bed system uses medium temperature heating and superheating sections, then the energy cost decreases, but the device complexity increases
Solution Approach 1:
The medium temperature heating section and superheating section are merged into a single integrated particle preheating section that combines both functions. This consolidation reduces device complexity by eliminating the need for separate heating systems while still achieving the energy cost reductions associated with medium temperature heating and the temperature enhancement benefits of superheating.
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 system achieves lower energy costs and CO2 footprint, enabling more economical production with manageable control processes and the ability to handle large solid carbon particles for energy storage.
Implementation Method 1
a medium temperature heating section configured to heat at least one of gases or particles to a first defined temperature
Implementation Method 2
an electrical system of a superheating section configured to heat the at least one of gases or particles received from the medium temperature heating section to a second defined temperature
Implementation Method 3
a high temperature section configured to receive the particles of the moving packed bed of particles that have been preheated in the particle preheating section and to transfer energy to the received particles to raise the temperature of the received particles to at least one of a decomposition temperature or a reaction temperature
Implementation Method 4
a decomposition and reaction section configured to receive the particles of the moving packed bed of particles whose temperature has been raised to the at least one of the decomposition temperature or the reaction temperature, to receive the feed gas interacting with the moving packed bed of particles, and to provide heat transfer between the particles of the moving packed bed of particles and the feed gas such that a reaction occurs that generates a gaseous product and a solid product
Data Source
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AI summary
A moving packed bed processing plant using medium temperature heating and superheating of process materials to produce gas and solid products is disclosed. In one form a system includes a reactor, a medium temperature heating section and a superheating section. The reactor includes a particle preheating section, a high temperature section, and a decomposition and reaction section with a moving packed bed of particles flowing through the sections of the reactor. The medium temperature heating section heats at least one of gases or particles to a first defined temperature. The superheating section heats the at least one of gases or particles received from the medium temperature heating section to a second defined temperature with an electrical system and provides the heated at least one gases or particles to the high temperature section of the reactor.