Phase Change Material Energy Storage for Chemical Process Heating
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Solution Overview
Problem
Chemical plants face challenges in maintaining consistent throughput during fluctuations in renewable energy availability and cost, as traditional energy storage methods are cost-prohibitive and technically challenging for large-scale energy requirements, especially when using phase change materials (PCMs) for heating processes.
Innovation Solution
Utilizing PCMs to store thermal energy by transitioning from a solid to a liquid state, releasing energy to supplement or replace external heating sources like fossil fuels or electricity, thereby maintaining consistent chemical process heating during peak or low energy availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If phase change materials are used to store thermal energy for large-scale chemical processes, then energy storage capacity is improved, but cost and technical complexity increase significantly
Solution Approach 1:
The patent utilizes phase change materials (PCMs) that transition between solid and liquid states to store and release thermal energy. During charging, the PCM absorbs thermal energy and transitions from solid to liquid state; during discharging, it releases thermal energy and transitions from liquid to solid state. This phase transition mechanism enables large-scale energy storage (2-500 MWh) suitable for chemical processes while maintaining manageable system complexity through the inherent physical properties of the PCM
Solution Approach 2:
The patent introduces a heat exchange system as an intermediary between the PCM and the chemical process. This heat exchange system facilitates thermal energy transfer without requiring direct integration between the PCM storage system and the chemical process equipment, thereby reducing technical complexity while maintaining large energy storage capacity
2Quantity of substance
If phase change materials are used to store thermal energy for large-scale chemical processes, then energy storage capacity is improved, but cost increases significantly
Solution Approach 1:
The patent employs phase change materials that leverage natural phase transitions to provide large-scale energy storage (2-500 MWh) at reduced cost compared to alternative storage methods. The PCM system replaces expensive fossil fuel infrastructure and avoids the high costs of conventional large-scale thermal energy storage, achieving cost-effective energy storage through the selection and deployment of appropriate phase change materials
Solution Approach 2:
The patent optimizes system parameters including PCM selection, storage temperature, and capacity sizing to achieve cost-effective large-scale energy storage. By adjusting these parameters, the system can provide 2-500 MWh of energy storage capacity while minimizing capital and operational costs, making large-scale energy storage economically viable for chemical processes
3Loss of energy
If external energy sources are reduced during peak hours, then energy cost is improved, but production consistency deteriorates
Solution Approach 1:
The patent implements energy storage charging during off-peak hours when energy costs are lower, storing thermal energy in advance for use during peak hours. This preliminary action allows the chemical plant to reduce or eliminate external energy purchases during expensive peak periods while maintaining continuous operation and production consistency through the stored thermal energy
Solution Approach 2:
The patent ensures continuous thermal energy supply to the chemical process by combining stored thermal energy from PCM discharge with process heating requirements. This continuity of useful action maintains consistent production rates and process temperatures even when external energy sources are reduced or eliminated during peak hours, thereby preserving production consistency while reducing energy costs
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 PCM system allows chemical plants to maintain constant production rates by storing and releasing thermal energy, reducing reliance on expensive or intermittent external energy sources, and optimizing energy costs through strategic charging and discharging cycles.
Implementation Method 1
A PCM is 'charged' by adding thermal energy from a heat source to transition the PCM from a first (e.g., solid) state to a higher-enthalpy second (e.g., liquid) state
Implementation Method 2
transition the PCM from a first (e.g., solid) state to a higher-enthalpy second (e.g., liquid) state
Implementation Method 3
the PCM can be then be 'discharged' by releasing thermal energy to the heating cycle
Implementation Method 4
releasing thermal energy to the chemical process that would have otherwise required further operation of heater(s) and/or evaporator(s)
Implementation Method 5
a heat-exchange system configured to communicate thermal energy from the PCM to the process
Data Source
AI summary
Systems and methods for storing and releasing thermal energy for heating in a process of a chemical plant. Some such systems may include a contained volume of phase change material (PCM); and a heat-exchange system configured to communicate thermal energy from the PCM to one or more of a chemical reactant, the chemical intermediate, or the chemical product; where the PCM is configured to transition from an first state to a higher-enthalpy second state at a transition temperature that is equal to or above a process temperature for the relevant chemical reactant, chemical intermediate or chemical product; and where the PCM requires at least 2 MWh to transition from the first state to the second state.