Modular Reactor Plate Elements for Uniform High-Temperature RWGS Heating
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Solution Overview
Problem
Existing reactors for converting CO2 into higher-value hydrocarbons face challenges in efficiently achieving high temperatures for endothermic reactions, such as rWGS, with high energy input requirements and significant heat loss, while being scalable and adaptable for various applications.
Innovation Solution
A reactor module comprising micro- or millistructured plate elements with separately controllable heating elements for reactant fluids, allowing direct heating and efficient thermal contact with the reaction zone, minimizing temperature gradients and heat loss, and enabling scalable and modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperatures (above 600°C) are used for endothermic rWGS reaction, then reaction efficiency is improved, but energy input requirements increase significantly
Solution Approach 1:
The reactor is divided into multiple plate elements with micro- or millistructured channels, creating segmented flow paths that increase surface area to volume ratio. This segmentation allows more efficient heat distribution throughout the reactant fluids, reducing the total energy input needed to achieve high temperatures while maintaining reaction efficiency.
Solution Approach 2:
Separately controllable heating elements are positioned at specific locations within the plate elements to create localized heating zones. This allows precise temperature control in different regions of the reactor, ensuring high temperatures are achieved only where needed for the reaction, thereby reducing overall energy input requirements while maintaining reaction efficiency.
2Productivity
If high temperatures are maintained for endothermic reactions, then reaction rate is improved, but heat loss increases significantly
Solution Approach 1:
Multiple plate elements are combined into a modular reactor system where the heating elements and reaction zones are integrated within the same structure. This merging reduces thermal isolation between heating and reaction zones, minimizing heat loss to the environment while maintaining high reaction rates through sustained high temperatures.
Solution Approach 2:
The separately controllable heating elements allow dynamic adjustment of temperature profiles in response to reaction conditions. This enables the system to maintain optimal high temperatures for reaction rate while reducing heating power when full temperature is not needed, thereby minimizing heat loss while preserving reaction rate.
3Adaptability or versatility
If modular and transportable reactor systems are designed, then scalability and adaptability are improved, but device complexity increases
Solution Approach 1:
The reactor is designed as a modular system of discrete plate elements that can be segmented and reconfigured for different applications and scales. Each plate element is a self-contained unit with integrated channels and heating elements, reducing the complexity of individual components while enabling scalable system assembly through simple stacking and connection of modules.
Solution Approach 2:
The plate elements are designed with universal features including standardized micro- or millistructured channels, catalyst support capabilities, and integrated heating elements that can accommodate various reactions and configurations. This universality allows the same basic module design to be adapted for different chemical reactions and scales, improving versatility without proportionally increasing device complexity.
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 solution achieves uniform heating of reactant fluids and catalysts at high temperatures with minimal heat loss, reducing unwanted side reactions and enhancing the efficiency of endothermic processes like rWGS, with improved scalability and adaptability for different applications.
Implementation Method 1
at least one heating element is in thermal contact with the reaction zone
Implementation Method 2
The plate element comprises or can accommodate at least one heating element, wherein at least one heating element is in thermal contact with the reaction zone
Data Source
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AI summary
The present invention relates to plate elements for constructing a reactor module for conducting endothermic reactions at high temperatures, wherein the plate elements are configured such that all reactant gases are heated by flowing around heating elements and the reaction zone is heated at the same time. The present invention also relates to reactor modules and reactor systems employing plate elements according to the invention pressed against one another, and also to the corresponding processes for efficiently conducting endothermic chemical reactions, especially the RWGS reaction.