Spirally Wound Conductors for Uniform RF Heating in Hydrocarbon Processing
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Solution Overview
Problem
The hydrocarbon upgrading process, particularly in the fluid catalytic cracking (FCC) process, faces inefficiencies, including limited efficiency, coke residue issues, increased risk of fires and explosions, poor molecular selectivity, and high reactant emissions, with existing RF heating methods often resulting in uneven heating and energy loss.
Innovation Solution
A hydrocarbon processing apparatus featuring a spirally wound electrical conductor surrounding and within a dielectric container, configured to generate parallel magnetic fields and filter electric fields, enhancing heating uniformity and efficiency by using RF energy to process hydrocarbon resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If RF energy is applied to heat hydrocarbon resources for cracking, then heating can be achieved, but energy loss occurs and heating uniformity is poor
Solution Approach 1:
The patent divides the RF heating system into two separate spirally wound electrical conductors: an outer conductor and an inner conductor. This segmentation allows each conductor to be optimized for its specific function - the outer conductor for generating magnetic fields and the inner conductor for filtering electric fields - thereby improving heating uniformity and reducing energy loss
Solution Approach 2:
The patent introduces a dielectric material as an intermediary between the two spirally wound electrical conductors. This dielectric material serves as a mediator that enables the coupling of magnetic and electric fields, improving energy transfer efficiency and heating uniformity while reducing direct energy loss
2Productivity
If FCC process is used for hydrocarbon cracking, then synthetic crude oil can be produced, but coke residues stop the process and increase fire/explosion risk
Solution Approach 1:
The patent changes the physical and chemical parameters of the hydrocarbon processing by applying dual RF field coupling through the two spirally wound conductors. This creates more uniform heating conditions that improve bitumen to gasoline conversion efficiency while reducing coke residue formation, thereby decreasing fire and explosion risks
3Temperature
If conventional RF heating is used, then hydrocarbon resources can be heated, but heating irregularities such as hot spots occur
Solution Approach 1:
The patent segments the RF heating function into two conductors with different orientations and functions. The outer conductor generates magnetic fields while the inner conductor filters electric fields, creating a more uniform heating pattern that eliminates hot spots
Solution Approach 2:
The patent applies local quality by having different regions of the heating system serve different functions - the outer conductor region generates magnetic fields for heating, while the inner conductor region filters electric fields to prevent hot spots, creating locally optimized heating conditions
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 solution increases the efficiency of hydrocarbon resource upgrading by achieving more uniform heating, reducing energy loss, and improving the conversion process of bitumen to gasoline, while minimizing the risks associated with coke residues and emissions.
Implementation Method 1
a first spirally wound electrical conductor surrounding the hydrocarbon processing container and coupled to the RF source
Implementation Method 2
The first spirally wound electrical conductor may be configured to generate magnetic fields within the hydrocarbon processing container being parallel with an axis thereof
Implementation Method 3
The second spirally wound electrical conductor may be carried within the hydrocarbon processing container transverse to the first spirally wound electrical conductor. The second spirally wound electrical conductor may be configured to filter electric fields within the hydrocarbon processing container
Implementation Method 4
a radio frequency (RF) source... applying radio frequency (RF) energy to a first spirally wound electrical conductor surrounding a hydrocarbon processing container
Data Source
AI summary
A device for processing a hydrocarbon resource may include a hydrocarbon processing container configured to receive the hydrocarbon resource therein and having a pair of opposing ends with an enlarged width medial portion therebetween. The device may also include a radio frequency (RF) source, and a first spirally wound electrical conductor surrounding the hydrocarbon processing container and coupled to the RF source. The device may further include a second spirally wound electrical conductor carried within the hydrocarbon processing container. The first spirally wound electrical conductor may be configured to generate magnetic fields with the hydrocarbon processing container that are parallel with an axis thereof.