Spirally Wound RF Conductor for Uniform Hydrocarbon Heating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The hydrocarbon upgrading process, particularly in the 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 non-uniform heating and energy loss.

Innovation Solution

A hydrocarbon processing apparatus featuring a spirally wound electrical conductor surrounding a dielectric container, coupled to an RF source, which generates uniform magnetic fields for improved heating efficiency and selectivity, utilizing a reactance element and conductive ring to adjust impedance and resonance frequencies for optimized energy distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional RF heating is applied to heat hydrocarbon resource, then heating can be achieved, but energy loss increases and heating uniformity deteriorates

Engineering Contradiction:

Improveheating uniformityVSAvoidenergy loss

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent employs a spirally wound RF conductor configured to generate spheroidal electromagnetic fields within the processing chamber. This curved field distribution pattern replaces conventional linear or planar heating approaches, enabling more uniform energy distribution throughout the hydrocarbon resource volume and reducing localized hot spots while improving overall heating efficiency

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The invention transitions from conventional two-dimensional surface heating to three-dimensional volumetric heating by positioning the spirally wound conductor to penetrate and distribute RF energy throughout the entire volume of the hydrocarbon resource. This dimensional transformation enables simultaneous heating of multiple zones, improving uniformity and reducing energy loss

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If FCC process is used for hydrocarbon cracking, then conversion can be achieved, but efficiency is limited and harmful factors increase

Engineering Contradiction:

Improveconversion efficiencyVSAvoidcoke residue and emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent applies RF heating at specifically selected frequencies and power levels to alter the thermal and chemical parameters of the hydrocarbon resource during processing. By controlling temperature profiles, heating rates, and energy distribution patterns, the process achieves improved conversion efficiency while minimizing coke formation and harmful emissions through optimized parameter management

Inventive Principle:

Principle #35Parameter changes

3Temperature

If conventional heating methods are used, then heating can be achieved, but hot spots are formed and temperature distribution becomes non-uniform

Engineering Contradiction:

Improvetemperature distributionVSAvoidheating consistency

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The spirally wound RF conductor generates spheroidal electromagnetic field patterns that naturally distribute energy more evenly throughout the processing chamber, eliminating the linear temperature gradients and localized hot spots characteristic of conventional heating methods. This curved field geometry ensures consistent heating across the entire hydrocarbon resource volume

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 enhances the efficiency and uniformity of hydrocarbon upgrading by reducing energy loss and hotspots, increasing the conversion rate of bitumen to gasoline, and minimizing emissions, while extending catalyst lifespan.

Implementation Method 1

a radio frequency (RF) source, and a spirally wound electrical conductor surrounding the hydrocarbon processing container and coupled to the RF source

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

application of RF to a hydrocarbon resource to heat the hydrocarbon resource for cracking

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Implementation Method 3

The spirally wound electrical conductor may be configured to generate magnetic fields within the hydrocarbon processing container being parallel with an axis thereof

Methodology Applied

Scientific EffectMagnetic field generation: Magnetic Field

Data Source

PatentUS8858785B2Hydrocarbon resource processing device including spirally wound electrical conductor and related methods

Publication Date: 2014.10.14 HARRIS CORP

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 spirally wound electrical conductor surrounding the hydrocarbon processing container and coupled to the RF source. The spirally wound electrical conductor may be configured to generate magnetic fields within the hydrocarbon processing container that are parallel with an axis thereof.