SiC Thermal Storage Units With Protective Coatings for 2000°C Heat
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Solution Overview
Problem
Existing high-temperature thermal storage systems face limitations in delivering process heat above 1000°C due to short material lifetime and high heat transfer costs, necessitating the development of stable and efficient thermal storage solutions for industrial applications.
Innovation Solution
Thermal storage units comprising silicon carbide (SiC) and composite materials like SiC-C, SiC-B4C, etc., configured for resistive heating up to 2000°C, with protective coating layers to enhance stability and longevity, and arranged in stacks for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional thermal storage materials are used for high-temperature storage (>1000°C), then energy storage capacity is achieved, but material lifetime becomes short and heat transfer cost increases
Solution Approach 1:
The patent employs composite materials consisting of silicon carbide particles embedded in a carbon matrix, creating a material that combines the high-temperature stability of SiC with the thermal shock resistance and toughness of carbon. This composite structure enables the material to withstand repeated thermal cycling at temperatures above 1000°C while maintaining structural integrity and extending operational lifetime
Solution Approach 2:
The invention modifies the physical and chemical parameters of the storage material by controlling the particle size, distribution, and composition of silicon carbide within the carbon matrix. By optimizing these parameters, the material achieves enhanced thermal conductivity, mechanical strength, and resistance to thermal degradation, allowing sustained high-temperature operation
2Use of energy by moving object
If conventional thermal storage materials are used for high-temperature storage (>1000°C), then energy storage capacity is achieved, but heat transfer cost becomes high
Solution Approach 1:
The patent optimizes thermal conductivity parameters by carefully selecting the carbon matrix composition and silicon carbide particle characteristics. This parameter optimization enhances heat transfer efficiency within the material, reducing the energy required for heat transfer operations and lowering overall heat transfer costs while maintaining high energy storage capacity
3Temperature
If silicon carbide composite materials are used for resistive heating to 2000°C, then high-temperature heat storage capability is improved, but material stability in corrosive atmospheres becomes challenging
Solution Approach 1:
The patent utilizes the synergistic properties of silicon carbide and carbon in composite form, where the carbon matrix provides chemical stability and resistance to oxidation in corrosive atmospheres, while silicon carbide contributes high-temperature structural stability. This composite approach enables the material to maintain compositional stability at temperatures up to 2000°C even in challenging atmospheric conditions
Solution Approach 2:
The invention employs a carbon-based composite that can be economically replaced if degradation occurs in extremely corrosive environments. The cost-effectiveness of the carbon-silicon carbide composite allows for periodic replacement rather than attempting to achieve indefinite stability, providing a practical solution for high-temperature applications where complete stability is difficult to achieve
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 SiC-based thermal storage units provide reliable and reusable high-temperature heat storage and transfer, reducing material degradation and operational costs, enabling consistent industrial process heat delivery.
Implementation Method 1
convert electricity into high-temperature heat via direct resistive heating
Implementation Method 2
store the heat in a storage device, and release the heat for an intended use during another time period
Implementation Method 3
release the heat for an intended use during another time period... deliver output energy in a different form, such as heat that is carried by a liquid or gas
Data Source
AI summary
Thermal storage units may comprise a substrate and one or more optional coatings configured to, for example, protect the substrate from, for example, corrosive environments, increase the thermal and/or chemical stability of the substrate and/or coating layers. The substrates may comprise silicon carbide and/or a composite material and may be configured to be resistively heated to temperatures within a range of 1000-2000° C. Heated thermal storage units may be exposed to a flow of heat transfer fluid that may absorb heat from the thermal storage units and, once heated, the flow of heat transfer fluid may be directed to industrial process equipment to provide heat thereto.