Resistively Heated TOC Reactor for Fast Supercritical Oxidation
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Solution Overview
Problem
Conventional methods for measuring total organic carbon (TOC) in aqueous samples are hindered by errors due to particulates, hardware failures from high salt concentrations, and inefficient heating and cooling processes, leading to inaccurate and time-consuming measurements.
Innovation Solution
A method and apparatus utilizing resistive heating to rapidly heat a reactor to supercritical conditions, combined with non-contact temperature measurement and rapid cooling, to convert organic carbon to carbon dioxide, allowing for precise and reproducible TOC measurements in a closed system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional external heating is used to heat the reactor to oxidation temperature, then the reactor can be heated to the required temperature, but the heating time is slow and temperature control is poor due to indirect heat transfer and radiation losses
Solution Approach 1:
The patent replaces the conventional external mechanical heating system with electrical resistive heating elements integrated directly into the reactor structure. This substitution enables direct heating of the reaction zone, eliminating the slow and inefficient external heat transfer process, thereby dramatically reducing heating time and improving temperature control precision.
Solution Approach 2:
The heating elements are nested within the reactor structure itself, with resistive heating wires embedded in the reactor walls or base. This nested configuration allows the heating elements to be in direct contact with the reaction zone, enabling rapid and efficient heat transfer while maintaining compact reactor design.
2Reliability
If the reactor is heated to high temperature for oxidation, then organic carbon can be converted to carbon dioxide, but high salt concentrations cause salt deposition in the furnace leading to clogging and hardware failures
Solution Approach 1:
The patent extracts the heating function from the external furnace environment and relocates it directly into the reactor through integrated resistive heating elements. This extraction eliminates the furnace chamber where salt deposition occurs, removing the source of clogging and hardware failures while maintaining the necessary high temperature for oxidation.
Solution Approach 2:
The patent changes the heating method from external thermal radiation to direct electrical resistive heating, fundamentally altering the thermal field distribution. This parameter change enables precise temperature control at the reaction zone without creating the conditions that lead to salt deposition and clogging in external furnaces.
3Measurement precision
If conventional heating methods are used, then the reactor can reach oxidation temperature, but temperature overshoot occurs and temperature control is not tight
Solution Approach 1:
The patent implements a feedback control system where temperature sensors continuously monitor the reaction zone temperature and provide real-time data to the control system. The control system adjusts the power supplied to the resistive heating elements based on this feedback, enabling precise temperature control and preventing overshoot by dynamically balancing heat input with thermal conditions.
4Productivity
If high temperature combustion is used to convert organic carbon to carbon dioxide, then TOC measurement can be performed, but the method is time-consuming and requires slow heating and cooling cycles
Solution Approach 1:
The patent employs periodic heating and cooling cycles optimized for rapid throughput. The resistive heating elements can be rapidly switched on and off, enabling short, intense heating pulses for oxidation followed by quick cooling phases. This periodic action dramatically reduces the total measurement cycle time compared to conventional continuous heating methods.
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 method achieves faster and more accurate TOC measurements by reducing heating time to 18 seconds, minimizing overshoot, and ensuring tight temperature control, while handling samples with high salt concentrations and particulates.
Implementation Method 1
a reactor heating system including an electrical current source operably connected to the reactor, the electrical current source configured to pass an electrical current through the reactor to rapidly and cyclically heat the reactor interior
Implementation Method 2
a sensor configured to determine a temperature value of the reactor... the sensor is configured to measure electromagnetic radiation
Implementation Method 3
the organic compounds in an aqueous sample are oxidized to carbon dioxide (CO2)... the sample is diluted as necessary, and then the sample enters the oxidation reactor where super critical water oxidation is used to effect the conversion of organic carbon to carbon dioxide
Data Source
AI summary
Apparatus and methods for measuring the concentrations of organic and inorganic carbon, or of other materials in aqueous samples are described, having a reactor that is resistively heated by passing an electric current through the reactor.