Resistance-Heated Structured Catalyst for Uniform Endothermic Reactors
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Solution Overview
Problem
Conventional heat transfer methods for endothermic reactions, such as steam reforming, are inefficient and slow, leading to temperature disparities within reactor units and potential unwanted side reactions.
Innovation Solution
A reactor system with a structured catalyst comprising an electrically conductive macroscopic structure coated with a ceramic material, integrated with a heat insulation layer and conductors for internal resistance heating, allowing precise temperature control and efficient heat transfer directly to the catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heat transfer methods (convection, conduction, radiation) are used to heat the catalyst bed, then the reactor can be designed with external heating, but the heat transfer is slow and inefficient, leading to large temperature disparities within the reactor
Solution Approach 1:
The patent replaces conventional mechanical/thermal heat transfer systems (external furnaces, heat exchangers) with an electrical heating system. Electrical conductors embedded within the catalyst bed directly generate heat through resistive heating, eliminating the need for slow external heat transfer through reactor walls and providing uniform temperature distribution throughout the catalyst bed.
Solution Approach 2:
The patent embeds electrical conductors directly within the catalyst bed structure, nesting the heating elements inside the reaction medium. This allows the heating system to be integrated into the catalyst support structure, enabling direct and efficient heat transfer to the catalyst particles without external heat transfer barriers.
2Volume of moving object
If external heating is used in conventional reactors, then the reactor structure can be simpler, but the reactor size must be larger to accommodate heat transfer requirements
Solution Approach 1:
The electrical conductors are nested within the catalyst bed and support structure, integrating the heating system into the existing reactor components. This integration eliminates the need for separate external heating systems and large reactor volumes, as the heating elements are distributed throughout the reaction zone.
Solution Approach 2:
The catalyst support structure serves multiple functions: it provides mechanical support for the catalyst, conducts electricity for heating, and facilitates gas flow. This multi-functionality reduces the need for separate heating system components, simplifying the overall device while reducing reactor volume.
3Loss of energy
If electrical resistance heating is applied to the catalyst bed, then heat transfer efficiency is improved, but the risk of overheating and unwanted side reactions increases
Solution Approach 1:
The patent incorporates temperature sensors distributed throughout the catalyst bed that continuously monitor temperature conditions. This feedback system allows for real-time adjustment of the electrical heating power, preventing localized overheating and maintaining temperatures within the optimal range for the desired reaction while avoiding unwanted side reactions.
Solution Approach 2:
The electrical heating system provides localized and uniform heat distribution throughout the catalyst bed, ensuring that each region receives exactly the heat it needs for the reaction. This prevents hot spots and localized overheating that could lead to cracking and unwanted side reactions, while still achieving high heat transfer efficiency.
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 enables efficient and compact heat supply to the catalyst, reducing reactor size, minimizing carbon dioxide emissions, and preventing side reactions by precise temperature control.
Implementation Method 1
the electrical power supply is dimensioned to heat at least part of the structured catalyst to a temperature of at least 200°C by passing an electrical current through the electrically conductive material
Implementation Method 2
a heat insulation layer between said structured catalyst and said pressure shell
Data Source
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AI summary
The invention relates to a reactor system for carrying out an endothermic reaction of a feed gas, comprising: - a structured catalyst arranged for catalyzing said endothermic reaction of a feed gas, said structured catalyst comprising a macroscopic structure of electrically conductive material, said macroscopic structure supporting a ceramic coating, wherein said ceramic coating supports a catalytically active material; - a pressure shell housing said structured catalyst; - heat insulation layer between said structured catalyst and said pressure shell; - at least two conductors electrically connected to said electrically conductive material and to an electrical power supply placed outside said pressure shell, wherein said electrical power supply is dimensioned to heat at least part of said structured catalyst to a temperature of at least 200°C by passing an electrical current through said electrically conductive material. The invention also relates to a process for performing an endothermic reaction of a feed gas.