Resistance-Heated Structured Catalyst for Uniform Endothermic Reactions
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Solution Overview
Problem
Conventional heat transfer methods for endothermic reactions, such as steam reforming, are inefficient and energy-intensive, leading to temperature gradients within reactors and high energy consumption, with conventional reactors being large and emitting significant carbon dioxide.
Innovation Solution
A structured catalyst system comprising a macroscopic structure of electrically conductive material with a ceramic coating and catalytically active material, utilizing a composite of conductive metallic and ceramic materials with varying resistivities to optimize heat flux and reduce the number of catalysts required, integrated with a reactor system for efficient endothermic reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional heat transfer methods (convection, conduction, radiation) are used to heat the catalyst bed, then the reactor system can carry out endothermic reactions, but the heat transfer efficiency is low and energy consumption is high
Solution Approach 1:
The patent replaces conventional thermal heat transfer mechanisms (convection, conduction, radiation) with electrical resistance heating. The structured catalyst itself becomes electrically conductive and generates heat directly when electrical current passes through it, eliminating the need for external heat transfer and significantly improving energy efficiency.
Solution Approach 2:
The structured catalyst performs self-heating through its own electrical resistance. When electrical current flows through the conductive catalyst structure, it generates the necessary heat for the endothermic reaction internally, without requiring external heating systems or heat transfer media.
2Volume of stationary object
If conventional externally heated reactors are used, then endothermic reactions can proceed, but the reactor size is large and temperature gradients occur within the reactor
Solution Approach 1:
The patent merges the catalyst structure with the heating element by making the catalyst itself electrically conductive. The catalyst structure serves dual functions: providing the catalytic surface for reaction and generating heat through electrical resistance, eliminating the need for separate heating systems and reducing reactor size.
Solution Approach 2:
The structured catalyst has spatially distributed electrical conductivity throughout its entire volume, allowing uniform heat generation across all regions. This ensures consistent temperature distribution and eliminates temperature gradients that occur in conventional externally heated reactors where heat must conduct from the exterior inward.
3Productivity
If the amount of catalytically active material is increased to improve reaction efficiency, then the reaction rate increases, but the reactor size and energy consumption increase
Solution Approach 1:
The patent uses composite materials with varying electrical resistivities distributed throughout the structured catalyst. This allows optimization of heat generation in different regions, enabling high reaction rates in areas with higher catalytic activity while maintaining energy efficiency, thus achieving high productivity without proportionally increasing reactor size.
Solution Approach 2:
The patent varies the electrical resistivity parameter across different regions of the structured catalyst to optimize both heat generation and catalytic activity. By adjusting resistivity, the system can control where and how much heat is generated, matching the heat supply to the local catalytic activity and maximizing reaction efficiency per unit volume.
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 achieves efficient heat transfer, reduces energy consumption, minimizes reactor size, and allows precise control of product gas temperature and pressure, while lowering carbon dioxide emissions when powered by renewable energy.
Implementation Method 1
utilizing a composite of conductive metallic and ceramic materials with varying resistivities to optimize heat flux
Implementation Method 2
the macroscopic structure at least partly is composed of two or more materials with different resistivities
Implementation Method 3
said ceramic coating supports a catalytically active material
Data Source
AI summary
Structured catalyst arranged for catalyzing an 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, wherein the electrically conductive material at least partly is a composite in the form of a homogenous mixture of an electrically conductive metallic material and a ceramic material, wherein the macroscopic structure at least partly is composed of two or more materials with different resistivities.