Thermal Heat Storage With Thermocline Discharge for Steam Cracking
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Solution Overview
Problem
Current thermal energy storage systems face challenges in efficiently storing and delivering high-temperature heat for industrial processes, particularly in 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, reducing reliance on fossil fuels 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 suffers from material limitations and reduced efficiency 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. These composite materials provide both thermal energy storage capacity and the necessary durability for high-temperature operation.
Solution Approach 2:
The system utilizes phase change materials that undergo controlled parameter changes (phase transitions) at specific high temperatures to store and release thermal energy. By selecting materials with appropriate melting and boiling points, the system optimizes heat storage capacity while maintaining material stability within operational temperature ranges.
2Loss of energy
If thermal energy storage systems lack dynamic insulation and advanced control, then the system structure is simpler, but heat loss increases and energy efficiency decreases
Solution Approach 1:
The patent implements dynamic insulation systems with adjustable insulation layers and movable thermal barriers that can be activated or deactivated based on operational requirements. This allows the system to adapt insulation levels dynamically, reducing heat loss during storage while maintaining operational flexibility.
Solution Approach 2:
The control system incorporates temperature sensors, heat loss monitoring, and automated adjustment mechanisms that continuously monitor thermal conditions and adjust insulation and heat transfer accordingly. This feedback loop optimizes energy retention while preventing excessive heat buildup, thereby reducing overall heat loss.
3Temperature
If thermal energy storage systems use fossil fuels for high-temperature heat generation, then sufficient heat can be produced, but greenhouse gas emissions increase
Solution Approach 1:
The patent replaces fossil fuel-based thermal combustion with electric heating elements and electromagnetic induction systems to generate high-temperature heat. This substitution eliminates direct carbon emissions from heat generation while maintaining the necessary temperature levels for industrial processes such as steam cracking.
Solution Approach 2:
The system utilizes electrically heated inert or controlled atmosphere environments to generate high temperatures without combustion, thereby avoiding greenhouse gas emissions. The inert atmosphere prevents unwanted chemical reactions while allowing efficient heat transfer to the thermal storage media.
4Productivity
If thermal energy storage systems lack optimized control based on forecasts and ambient conditions, then the control system is simpler, but energy delivery efficiency and cost-effectiveness decrease
Solution Approach 1:
The control system incorporates forecasting capabilities that predict future energy demand and ambient conditions, allowing the system to pre-charge thermal storage units during periods of low demand or favorable conditions. This preliminary action optimizes energy availability and delivery efficiency during peak demand periods.
Solution Approach 2:
The advanced control system continuously monitors ambient conditions, storage charge levels, and energy demand patterns, adjusting heat transfer rates, insulation activation, and discharge timing accordingly. This real-time feedback optimization maximizes energy delivery efficiency and cost-effectiveness by aligning thermal energy release with actual demand 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 system enables efficient, continuous, and cost-effective delivery of high-temperature heat, reducing environmental impact and operational costs by optimizing energy storage and use, while maintaining system integrity and longevity.
Implementation Method 1
thermal energy storage system that stores electrical energy in the form of thermal energy
Implementation Method 2
vertically oriented thermal storage units with insulative layers and dynamic insulation
Implementation Method 3
each of the heaters being connected to the input electricity
Implementation Method 4
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.