Phase Change Material Thermal Storage for Chemical Plant Heating
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Solution Overview
Problem
Chemical plants face challenges in maintaining consistent throughput during fluctuations in electricity availability and cost from renewable sources, as traditional energy storage methods are cost-prohibitive and technically challenging for large-scale thermal energy storage.
Innovation Solution
Utilizing phase change materials (PCMs) to store and release thermal energy, transitioning from a solid to a liquid state, to supplement or replace external heating sources like fossil fuels or electricity, thereby maintaining consistent chemical process heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional energy storage methods are used for large-scale thermal energy storage in chemical plants, then energy availability can be maintained during peak hours, but the cost becomes prohibitively expensive and technical challenges increase
Solution Approach 1:
The patent applies phase transition of paraffin wax from solid to liquid state to store thermal energy. During off-peak hours, paraffin is heated and melts, storing energy. During peak hours, the melting process continues, releasing stored thermal energy to maintain process heating requirements. This phase change mechanism provides a simple, cost-effective solution for large-scale thermal energy storage without complex technical systems
Solution Approach 2:
The system performs preliminary heating and melting of paraffin during off-peak hours when electricity is cheaper and more abundant. This advance preparation stores thermal energy that can be drawn upon during peak hours, effectively shifting energy consumption to optimize cost and availability
2Use of energy by moving object
If phase change materials are used to store large amounts of thermal energy (at least 2 MWh), then external power requirements during peak hours are reduced, but the mass/volume of PCM required becomes very large
Solution Approach 1:
The patent utilizes the latent heat of fusion of paraffin wax during phase transition from solid to liquid. This phase change enables storage of large amounts of thermal energy (2-500 MWh) in a relatively compact form, as the energy is stored within the material's phase transformation rather than requiring separate storage infrastructure
Solution Approach 2:
The system changes the temperature parameter of paraffin during charging (heating to melt) and discharging (maintaining melting temperature). By controlling temperature parameters and utilizing the phase transition point, the system optimizes energy storage density and reduces the mass of PCM required for a given energy capacity
3Productivity
If chemical plants maintain consistent throughput during peak hours, then production stability is improved, but external energy demand increases when electricity is most expensive
Solution Approach 1:
The system performs preliminary energy storage during off-peak hours by heating and melting paraffin when electricity is cheaper. This advance energy accumulation allows the plant to maintain full production throughput during peak hours without incurring high energy costs, as the stored thermal energy from paraffin melting supplies the heating requirements
Solution Approach 2:
The paraffin melting process provides continuous thermal energy supply during peak hours, ensuring uninterrupted process heating and maintaining consistent chemical production throughput. The system bridges the gap between energy availability and production requirements, enabling continuous operation without interruption
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
Enables chemical plants to maintain constant production rates by storing thermal energy during off-peak hours, reducing external energy demand during peak hours, and utilizing renewable energy sources effectively.
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
the PCM can be then be 'discharged' by releasing thermal energy to the heating cycle
Implementation Method 3
a heat-exchange system configured to communicate thermal energy from the PCM to one or more of a chemical reactant, a chemical intermediate, or the molecular product
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
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.