Replaceable Catalytic Cartridge for LPG Tank Heating
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Solution Overview
Problem
Existing LPG tank heating systems face challenges in maintaining tank pressure at low ambient temperatures, leading to reduced heating efficiency and potential system malfunctions, especially in remote locations where electrical heating elements are impractical and servicing is burdensome due to complex configurations and safety regulations.
Innovation Solution
A catalytic heating system with a replaceable catalytic cartridge that can be easily on-site replaced, coupled to an LPG storage tank, which uses vapor from the tank to regulate heat output and maintain pressure, eliminating the need for remote servicing and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electric heating elements are used to maintain tank pressure at low temperatures, then heating efficiency is improved, but safety risks and complexity increase due to electrical connections in hazardous locations
Solution Approach 1:
The patent replaces electric heating elements with a catalytic heater that uses chemical combustion of LPG vapor to generate heat. This substitution eliminates electrical connections in hazardous locations, removing the safety risks associated with electric heating while maintaining the ability to heat the tank and maintain pressure at low temperatures.
Solution Approach 2:
The catalytic heater is designed to use LPG vapor from the tank itself as fuel, creating a self-service system. The tank's own contents provide the energy needed for heating, eliminating the need for external power sources or complex electrical infrastructure, thereby reducing safety risks and system complexity.
2Temperature
If catalytic heaters with fixed catalyst layers are used, then heating function is provided, but servicing becomes burdensome requiring remote facility transport
Solution Approach 1:
The patent divides the catalytic heater into separable components: a reusable heater body and replaceable cartridges containing the catalyst layer. This segmentation allows the catalyst cartridge to be independently removed and replaced at the site, eliminating the need to transport the entire heater to remote facilities for servicing.
Solution Approach 2:
The catalyst cartridge is designed as a disposable or replaceable component that can be easily discarded after use and replaced with a fresh cartridge. This approach simplifies servicing by allowing quick on-site replacement without complex recovery or regeneration processes, directly addressing the ease of repair concern.
3Reliability
If complex heater configurations are used to ensure safety compliance, then safety is improved, but system complexity and installation difficulty increase
Solution Approach 1:
The patent employs disposable catalyst cartridges that are pre-certified for safety compliance. These ready-to-use cartridges eliminate the need for complex installation procedures or complex certification processes, as each cartridge is independently tested and approved. This approach maintains safety compliance while reducing system complexity and installation difficulty.
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 system effectively maintains tank pressure and heating efficiency by allowing on-site replacement of catalytic cartridges, reducing downtime and operational costs, and ensuring safety compliance by avoiding direct electrical connections and complex configurations.
Implementation Method 1
a catalytic heating system with a replaceable catalytic cartridge that can be easily on-site replaced, coupled to an LPG storage tank, which uses vapor from the tank to regulate heat output and maintain pressure
Implementation Method 2
As gas vapor is drawn from the tank for use, the pressure in the tank drops, allowing more of the liquefied gas to boil to vapor, which increases or maintains pressure in the tank. As the gas boils, the phase change from liquid to gas draws thermal energy from the remaining liquid, which tends to reduce the temperature of the LPG in the tank.
Data Source
AI summary
A catalytic tank heater includes a removably attached catalytic heater cartridge having catalytic material. The heater is attached to an LPG tank to position the catalytic heater cartridge to face the tank. The catalytic heater cartridge covers a plenum chamber of the catalytic tank heater. A fuel distribution header and heating element are positioned within the plenum chamber and are controlled to initiate combustion of the catalytic material to heat the tank. Vapor from the tank is provided as fuel to the catalytic tank heater, and is regulated to increase heat output as tank pressure drops. The catalytic heater cartridge can be replaced with a new cartridge while at the location of the tank on a property.