Self-Heated Catalytic Reactor with Internal Resistive Preheating
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Solution Overview
Problem
Catalytic heaters require pre-heating of their catalysts to high temperatures, typically achieved using external resistive heaters, which is energy-intensive and challenging due to thermal mass and integration issues, slowing down the heating process and increasing energy consumption.
Innovation Solution
A self-heated catalytic reactor design featuring a conductive layer and insulator layer stack with electrodes for internal resistive heating, where the catalyst layer is supported on both layers, allowing for efficient pre-heating by passing an electric current through the conductive layer, reducing the time and energy needed to reach operating temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an externally-positioned resistive heater is used to preheat the catalyst, then the catalyst can reach operating temperature, but the heating process consumes a lot of energy and takes a long time due to the housing's thermal mass
Solution Approach 1:
The patent merges the heating function with the catalyst support structure by making the conductive layer both the structural support for the catalyst and the resistive heating element. This integration eliminates the need for a separate external heater and reduces the thermal mass that must be heated, as the housing is no longer required for structural support.
Solution Approach 2:
The patent extracts the housing from the system by using a self-supported catalyst layer structure. The conductive catalyst support layer provides its own mechanical strength and structural integrity, allowing the housing to be removed entirely. This reduces the overall thermal mass and energy required for heating.
2Temperature
If an externally-positioned resistive heater is used to preheat the catalyst, then the catalyst can reach operating temperature, but the integration is challenging due to high operating temperatures, available space, and flow requirements
Solution Approach 1:
The heating function and catalyst support function are merged into a single component - the conductive catalyst support layer. This eliminates the need for separate heater integration and resolves the complexity issues associated with fitting external heaters into the limited space while maintaining proper flow paths and thermal management.
3Temperature
If the housing is used to transfer heat to the catalyst layer, then heating can be achieved, but the significant thermal mass of the housing slows down the heating process
Solution Approach 1:
The patent removes the housing from the heat transfer path by making the catalyst layer self-supported. Without the housing's significant thermal mass, the heating process is dramatically accelerated as heat is applied directly to the thin conductive support layer and catalyst, which have minimal thermal inertia.
Solution Approach 2:
The conductive catalyst support layer functions as a thin film structure that replaces the bulky housing. This thin film has negligible thermal mass compared to the housing, allowing rapid heating while still providing the necessary mechanical support for the catalyst particles.
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 approach significantly reduces the time and energy required to preheat the catalyst layer, enabling faster and more efficient heating of catalytic reactors, allowing for earlier introduction of fuel and oxidant, and minimizing thermal mass while maintaining mechanical support.
Implementation Method 1
The catalyst layer is preheated by passing an electric current through the two electrodes and resistively heating the conductive layer
Data Source
AI summary
Described herein are catalytic heating systems comprising self-heated catalytic reactors and methods of operating thereof. A self-heated catalytic reactor comprises a corrugated conductive layer and an insulator layer forming a stack (e.g., a wound stack) such that each pair of adjacent conductive layers in the stack is separated by an insulator layer. The self-heated catalytic reactor also comprises a catalyst layer, positioned on one or both conductive and insulator layers, and two electrodes electrically coupled to the conductive layer at the opposite ends. The catalyst layer is preheated by passing an electric current through the two electrodes and resistively heating the conductive layer, in some examples, supporting at least a portion of the catalyst layer. This internal heating reduces the time and energy required to bring the catalyst layer to its operating temperature, at which point the fuel can be introduced to provide additional heating.