Thermal Heat Storage for Continuous Steam Cracking Furnaces
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Solution Overview
Problem
Current thermal energy storage systems face challenges in efficiently storing and delivering high-temperature heat, particularly for industrial applications like steam cracking, due to limitations in materials, design, and control systems, leading to inefficiencies and environmental impacts such as high greenhouse gas emissions.
Innovation Solution
A thermal energy storage system that utilizes vertically oriented thermal storage units with insulative layers and dynamic insulation, coupled with a control system that manages energy based on forecasts and ambient conditions, to efficiently store and deliver high-temperature heat from variable renewable energy sources, integrating with steam cracking furnaces to reduce fossil fuel consumption and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal energy storage systems use conventional materials and design for high-temperature heat storage, then the system can store thermal energy, but the system reliability and longevity are compromised due to material limitations at high temperatures
Solution Approach 1:
The patent employs composite materials including refractory bricks, ceramic fibers, and specialized heat-resistant coatings to construct thermal storage units capable of withstanding high temperatures while maintaining structural integrity and reliability over extended operational periods
Solution Approach 2:
Different regions of the thermal storage system utilize materials with locally optimized properties - for example, the inner lining near the heat source uses materials with highest temperature resistance, while outer layers use materials optimized for insulation and structural support
2Loss of energy
If thermal energy storage systems use static insulation design, then the system structure is simple, but heat loss increases reducing energy storage efficiency
Solution Approach 1:
The system implements dynamic insulation adjustment mechanisms that adapt insulation properties based on operational conditions - for instance, adjusting air gaps or insulation material density in response to temperature changes and heat loss patterns to optimize thermal efficiency while managing system complexity
Solution Approach 2:
Temperature sensors and control systems monitor heat loss in real-time and adjust insulation configurations accordingly, creating a feedback loop that maintains optimal thermal efficiency by dynamically responding to changing operational conditions
3Use of energy by moving object
If thermal energy storage systems deliver heat continuously without control optimization, then the system operates simply, but energy efficiency decreases and operational costs increase
Solution Approach 1:
The control system utilizes temperature sensors, flow meters, and predictive algorithms to continuously monitor system state and adjust heat delivery parameters, creating a feedback-controlled system that optimizes energy efficiency by matching heat output to actual demand patterns and forecasting future requirements
Solution Approach 2:
The system employs predictive control that pre-adjusts insulation and heat delivery parameters based on forecasted demand patterns and environmental conditions, performing preliminary optimization actions before peak demand periods occur to maximize energy efficiency
4Temperature
If steam cracking systems use fossil fuel combustion for heat generation, then the system can achieve required temperatures, but greenhouse gas emissions increase
Solution Approach 1:
The system transitions from chemical energy combustion to electrical energy heating, fundamentally changing the energy source parameter while maintaining the required temperature output for steam cracking, thereby eliminating direct greenhouse gas emissions from the heat generation process
Solution Approach 2:
The patent replaces the mechanical/chemical combustion system with an electrical heating system, substituting the combustion process with electric resistance or induction heating that delivers equivalent thermal energy without producing greenhouse gas emissions
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 system enables efficient, continuous, and cost-effective storage and delivery of high-temperature heat, reducing fossil fuel use and greenhouse gas emissions while maintaining system reliability and longevity.
Implementation Method 1
A thermal energy storage system that utilizes vertically oriented thermal storage units with insulative layers and dynamic insulation, coupled with a control system that manages energy based on forecasts and ambient conditions, to efficiently store and deliver high-temperature heat from variable renewable energy sources
Implementation Method 2
vertically oriented thermal storage units with insulative layers and dynamic insulation
Implementation Method 3
provides higher-temperature heat to a steam cracking furnace system for converting a hydrocarbon feedstock into cracked gas
Data Source
AI summary
An energy storage system (TES)converts variable renewable electricity (VRE) to continuous heat at over 1000° C. Intermittent electrical energy heats a solid medium. Heat from the solid medium is delivered continuously on demand. Heat delivery via flowing gas establishes a thermocline which maintains high outlet temperature throughout discharge. The delivered heat which may be used for processes including power generation and cogeneration. In one application, the energy storage system provides higher-temperature heat to a steam cracking furnace system for converting a hydrocarbon feedstock into cracked gas, thereby increasing the efficiency of the temperature control.