Reactor assemblies and methods of performing reactions
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Solution Overview
Problem
Current reactor systems face issues with hot spots and thermal stress due to imperfections in solar concentrator optics, leading to reduced reactor lifetime and increased costs, as well as inefficiencies in energy utilization in endothermic reactions like steam methane reforming.
Innovation Solution
The design incorporates stacked reactor assemblies with non-linear fluid channels oriented in thermal contact, allowing for thermal spreading and energy recuperation, utilizing solar energy and exothermic processes to drive endothermic reactions, such as methane steam reforming, through a spiral counter-cross-flow pattern that reduces thermal stress and enhances energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional steam methane reforming systems are used, then hydrogen production can be achieved, but thermal stress and hot spots reduce 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 distributes the thermal stress and prevents concentration of hot spots in a single location, thereby extending reactor lifetime while maintaining hydrogen production capacity
Solution Approach 2:
The serpentine (curved) channel configuration replaces straight linear paths with curved trajectories. This curvature distributes thermal stress more evenly along the channel walls and prevents sharp temperature gradients at corners or joints, reducing thermal fatigue and extending reactor operational life
2Use of energy by moving object
If solar concentrator optics are used to drive endothermic reactions, then energy efficiency improves, but optical imperfections create hot spots and thermal stress
Solution Approach 1:
The serpentine channel configuration provides different thermal exposure characteristics at different locations within the reactor. The curved paths create varying residence times and thermal contact areas with the reactor wall, allowing local adaptation to non-uniform solar flux distribution and preventing hot spot formation despite optical imperfections
Solution Approach 2:
The serpentine pattern transforms the simple linear one-dimensional heat transfer path into a two-dimensional distributed thermal field. This dimensional change spreads the thermal load across a larger area and multiple pathways, reducing peak temperatures and thermal stress concentrations caused by localized optical imperfections
3Device complexity
If linear fluid channels are used, then reactor design is simple, but energy utilization efficiency is reduced
Solution Approach 1:
The serpentine curved channel configuration maximizes the heat transfer surface area within a compact reactor footprint. The curved paths increase the effective thermal contact length between the fluid and reactor wall without proportionally increasing reactor volume, thereby improving energy utilization efficiency while maintaining relatively simple device architecture
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 configuration reduces hot spots, extends reactor lifetime, and improves energy efficiency by up to 85% thermal-to-chemical energy conversion, making the system more productive and cost-effective by effectively managing thermal stress and energy distribution.
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
heat for the channels can be provided from a variety of sources, including electrical heating, exothermic chemical processes, and/or solar energy
Implementation Method 3
utilize thermal energy to facilitate or drive an endothermic reaction in at least one of the sets of fluid channels
Implementation Method 4
heat for the channels can be provided from a variety of sources, including electrical heating, exothermic chemical processes
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 where the channels of either one or both of the first of the set of fluid channels are non-linear. 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.