Method and apparatus for heating fluids in processes related to refining and petrochemical industries using rotary generated thermal energy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Industrial processes in oil refining and petrochemical industries face challenges in achieving high temperatures efficiently while minimizing greenhouse gas and particle emissions, as conventional technologies struggle with energy efficiency and emission reduction at high-temperature conditions.
Innovation Solution
A rotary apparatus is integrated into refining and petrochemical facilities to generate a heated fluidic medium by imparting thermal energy through a series of energy transformations within the apparatus, using electrical energy and capable of reaching temperatures up to 1700°C, replacing conventional fuel-fired heaters and enabling indirect heating with reactive compounds for further temperature increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional fuel-fired heaters are used for high-temperature processes, then high temperatures (400-450°C or higher) can be achieved, but greenhouse gas emissions and particle emissions increase significantly
Solution Approach 1:
The patent replaces the combustion-based thermal system with an electrified rotary heating system. The rotary heater uses electrical energy to drive a rotor that generates thermal energy through electromagnetic induction and mechanical friction, eliminating the need for fuel combustion and thereby eliminating CO2 and other greenhouse gas emissions while maintaining the capability to achieve high temperatures required for refining and petrochemical processes
Solution Approach 2:
The invention changes the energy source parameter from chemical energy (fuel combustion) to electrical energy. The rotary heater converts electrical energy into thermal energy through electromagnetic fields and mechanical rotation, fundamentally altering the energy transformation pathway to eliminate harmful emissions while maintaining the temperature parameter required for industrial processes
2Temperature
If conventional fuel-fired heaters are used for high-temperature processes, then high temperatures can be achieved, but energy efficiency deteriorates due to high fuel consumption
Solution Approach 1:
The patent replaces the inefficient combustion process with an electrified rotary heating system that directly converts electrical energy to thermal energy. This substitution eliminates energy losses associated with combustion inefficiency, heat transfer through flue gases, and incomplete burning, thereby improving overall energy efficiency while maintaining the required temperature output
Solution Approach 2:
The rotary heater is designed to self-regulate its thermal energy generation through the interaction of the rotating rotor with the fluid medium. The system automatically adjusts its energy conversion to match process requirements, reducing wasteful energy consumption while maintaining optimal temperature levels for refining operations
3Temperature
If conventional fuel-fired heaters are used for high-temperature processes, then high temperatures can be achieved, but particle emissions and soot formation increase
Solution Approach 1:
The patent eliminates the combustion process entirely by replacing it with an electrified rotary heating mechanism. This substitution removes the source of particle emissions and soot formation that inherently occur during fuel combustion, while still achieving the high temperatures necessary for refining and petrochemical processes through direct electrical energy conversion
4Object-generated harmful factors
If electrified heaters are used to reduce emissions, then greenhouse gas emissions decrease, but the ability to achieve high temperatures deteriorates
Solution Approach 1:
The rotary heater employs dynamic rotational motion to generate high temperatures. The rotating rotor creates continuous mechanical energy conversion and electromagnetic induction, generating intense localized heating that can reach the high temperatures (400-450°C and above) required for refining processes, thereby overcoming the temperature limitation of static electrified heaters
Solution Approach 2:
The rotary heating system uses periodic rotational cycles to maintain high temperatures. The continuous rotation of the rotor creates repeated cycles of energy conversion and heat generation, ensuring sustained high-temperature output necessary for industrial processes while maintaining zero greenhouse gas emissions through electrical energy input
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
This solution improves energy efficiency, reduces greenhouse gas and particle emissions, and allows for the use of renewable energy, offering a cost-effective and environmentally friendly alternative for high-temperature processes, while also enabling the electrification of steam cracking processes.
Implementation Method 1
an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through the stationary vanes and the at least one row of rotor blades
Data Source
AI summary
A method is provided for inputting thermal energy into fluidic medium in a process or processes related to oil refining and/or petrochemical industries by at least one rotary apparatus comprising a casing with at least one inlet and at least one exit, a rotor comprising at least one row of rotor blades arranged over a circumference of a rotor hub mounted onto a rotor shaft, and a stator configured as an assembly of stationary vanes arranged at least upstream of the at least one row of rotor blades. In the method, an amount of thermal energy is imparted to a stream of fluidic medium directed along a flow path formed inside the casing between the inlet and the exit by virtue of a series of energy transformations occurring when said stream of fluidic medium passes through stationary and rotating components of said rotary apparatus, respectively. The method further comprises: integration of said at least one rotary apparatus into a heat-consuming process facility configured as a refining and/or petrochemical facility and further configured to carry out heat-consuming process or processes related to refining of oil and/or producing petrochemicals at temperatures essentially equal to or exceeding 500 degrees Celsius (° C.), and conducting an amount of input energy into the at least one rotary apparatus integrated into the heat-consuming process facility, the input energy comprises electrical energy. A rotary apparatus and related uses are further provided.