Electrically Heated Packed Reactor with Segmented Electrodes
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Solution Overview
Problem
Current reactor designs for high-temperature endothermic reactions face challenges in efficiently introducing and distributing electrical energy, leading to high energy losses and complex constructions due to the need for electrodes in hot regions, which causes heat bridging, mechanical stress, and non-uniform heating.
Innovation Solution
A pressure-bearing, electrically heated reactor with a vertical arrangement of electrodes embedded in conductive packing, where the upper and lower sections are insulated from the middle section, allowing for uniform electrical distribution and high thermal integration by minimizing energy dissipation through large cross-sectional connecting elements and grid electrode designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electrodes are placed in hot regions for direct heating, then heating efficiency is improved, but mechanical stress and heat bridging increase
Solution Approach 1:
The reactor is divided into three separate sections (upper, middle, lower) that are electrically insulated from each other. The electrodes are placed only in the upper and lower sections, while the middle section remains electrically isolated. This segmentation prevents heat bridging through electrode supports and reduces mechanical stress on single structural components.
Solution Approach 2:
Electrically insulating materials are introduced as intermediaries between the electrodes and the reactor wall, and between the upper and lower sections. These intermediaries allow electrical current to flow through the packing material directly while preventing unwanted heat transfer and mechanical stress concentration.
2Power
If electrodes are used for direct electrical heating, then energy input is improved, but construction complexity increases due to insulation requirements
Solution Approach 1:
The reactor is divided into three separate sections (upper, middle, lower) that are electrically insulated from each other. The electrodes are placed only in the upper and lower sections, while the middle section remains electrically isolated. This segmentation simplifies the insulation design by creating distinct electrical zones rather than requiring complex insulation throughout the entire reactor.
Solution Approach 2:
Electrical insulation is applied locally only where needed - specifically between the upper and lower sections and in the middle section - rather than throughout the entire reactor. This localized approach reduces overall construction complexity while maintaining the necessary electrical isolation for direct heating.
3Loss of energy
If solid heat carriers are heated in separate combustion chambers, then heat integration is improved, but thermal and mechanical stress on reactors increase
Solution Approach 1:
The heating function and reaction function are merged into a single reactor vessel. Direct electrical heating elements are placed within the reactor to heat the reaction mixture in situ, eliminating the need for separate combustion chambers and heat carrier circulation systems. This reduces thermal stress on the reactor while maintaining effective heat integration.
4Loss of energy
If heat transfer surfaces are used for heat exchange, then heat integration is improved, but fouling and material demands increase
Solution Approach 1:
The mechanical heat transfer surface system is replaced with direct electrical heating elements embedded in the reaction mixture. This substitution eliminates the solid-liquid interface that causes fouling, while maintaining effective heat transfer through direct Joule heating of the reaction contents.
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 over 99% electrical power release in the heated zone with uniform heating and high thermal integration, reducing energy losses and mechanical stress, while allowing for scalable and simple reactor configurations.
Implementation Method 1
having an electrically conductive solid-state packing... at least one pair of electrodes in a vertical arrangement which is connected via the pressure-bearing apparatus shell... for performance of endothermic reactions with direct electrical heating
Data Source
AI summary
The present invention relates to an electrically heatable packed pressure-bearing apparatus for conducting endothermic reactions having an upper (3), middle (1) and lower (3) apparatus section, where at least one pair of electrodes (4, 5) in a vertical arrangement is installed in the middle section (1) and all electrodes are disposed in an electrically conductive solid-state packing (26), the upper and lower apparatus sections have a specific conductivity of 105 S/m to 108 S/m, and the middle apparatus section is electrically insulated against the solid-state packing, wherein the upper and lower apparatus sections are electrically insulated from the middle apparatus section, the upper electrode is connected via the upper apparatus section and the lower electrodes via the lower apparatus section or the electrodes are each connected via one or more connecting elements (10, 16) that are in electrical contact with these sections and the ratio of the cross-sectional areas of the upper and lower electrode to the cross-sectional area of the respective current-conducting connecting element or, without use of a connecting element, the ratio of the cross-sectional area of the upper and lower electrode to the cross-sectional area of the respective current-conducting apparatus section is 0.1 to 10.