Thermal Generation System for Pressure Vessels

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Application No. 63/627,519 filed Jan. 31, 2024, the disclosure of which is incorporated herein by reference.

FIELD

The present disclosure is generally directed to pressure vessels in the oil and gas industry and, more particularly, to a thermal generation system arranged within a pressure vessel to increase the general temperature of a fluidized particulate stream.

BACKGROUND

The fluidization of particulate solids using circulating fluidized-bed (CFB) processes is prevalent in various aspects of the oil and gas refining and petrochemical industry (collectively “oil and gas industry”). CFB processes may be carried out in various oil and gas industry equipment, such as pressure vessels (e.g., reactor vessels, furnace vessels, regenerator vessels, etc.), transfer lines (pipes), and the like. The fluidized matter within CFBs often requires a specific operating temperature to complete the process objective, and there are many known methods of changing the process temperature of a catalyst and/or particles for such catalytic fluidized applications. Some relevant industry examples may use high temperature steam, microwave energy, magnetic conductive heating, gas firing, and/or electric hardware as a means of elevating the temperature of the fluidized matter.

Commercially known systems, however, are fluid process, electrically, and/or mechanically challenging. Improved and more efficient systems and methods of heating catalyst and/or particles within pressure vessels are required for certain applications.

SUMMARY OF DISCLOSURE

Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter.

The present disclosure describes a pressure vessel that includes an inlet port through which a particulate stream is introduced into an interior of the pressure vessel, a discharge port through which a heated fluidized particulate stream is discharged from the interior of the pressure vessel, and a thermal generation system arranged within the interior of the pressure vessel and operable to increase a temperature of the particulate stream and thereby produce the heated fluidized particulate stream. The thermal generation system includes one or more electric thermal bundles, and each electric thermal bundle includes a plurality of spaced-apart, electric thermal conduits arranged in series and extending substantially vertical within the pressure vessel, each electric thermal conduit being operable to generate and radiate thermal energy into the interior of the pressure vessel, and a distribution bus bar electrically coupled to each electric thermal conduit, and a second distribution bus bar electrically coupled to each electric thermal conduit to complete the circuit.

The present disclosure also describes a method of heating a fluidized particulate stream that includes introducing a particulate stream into an interior of a pressure vessel via an inlet port, and fluidizing and increasing a temperature of the fluidized particulate stream with a thermal generation system and thereby producing a heated fluidized particulate stream. The thermal generation system may be arranged within the interior of the pressure vessel and may include one or more electric thermal bundles. Each electric thermal bundle may include a plurality of spaced-apart, electric thermal conduits arranged in series and extending substantially vertical within the pressure vessel, each electric thermal conduit being operable to generate and radiate thermal energy into the interior of the pressure vessel, a first distribution bus bar electrically coupled to each electric thermal conduit, and a second distribution bus bar electrically coupled to each electric thermal conduit to complete the circuit. The method may further include discharging the heated fluidized particulate stream from the interior of the pressure vessel via a discharge port.

The present disclosure further describes a pressure vessel that includes an inlet port through which a fluid stream is introduced into an interior of the pressure vessel and fluidized, a discharge port through which a heated fluid stream is discharged from the interior of the pressure vessel, a thermal generation system arranged within the interior of the pressure vessel and operable to increase a temperature of the fluid stream and thereby produce the heated fluid stream, the thermal generation system including one or more electric thermal bundles. Each electric thermal bundle includes a plurality of spaced-apart, electric thermal conduits arranged in series and extending substantially vertical within the pressure vessel, each electric thermal conduit being operable to generate and radiate thermal energy into the interior of the pressure vessel, a distribution bus bar electrically coupled to each electric thermal conduit, and a second distribution bus bar electrically coupled to each electric thermal conduit.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures are included to illustrate certain aspects of the disclosure, and should not be viewed as exclusive configurations. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, as will occur to those skilled in the art and having the benefit of this disclosure.

FIG. 1 is schematic front view of an example pressure vessel that may incorporate one or more principles of the present disclosure.

FIG. 2 is a schematic top, cross-sectional view of the system of FIG. 1, according to one or more embodiments.

FIG. 3 is another schematic cross-sectional side view of the pressure vessel of FIG. 1, according to one or more additional embodiments.

FIGS. 4A and 4B are enlarged, schematic front and top views, respectively, of an example electric thermal bundle, according to one or more embodiments.

FIG. 5 is an enlarged cross-sectional front view of an example of the vessel nozzle of FIG. 1, according to one or more embodiments.

FIG. 6 is a cross-sectional side view of the upper and lower portions of the electric thermal bundle of FIGS. 4A and 4B, according to one or more embodiments.

FIG. 7 is a cross-sectional side view of the entire assembled electric thermal bundle of FIG. 6, according to one or more embodiments.

FIG. 8 is a cross-sectional top view of the assembled electric thermal conduit as taken along the lines A-A in FIG. 7, according to one or more embodiments.

FIG. 9 is a cross-sectional top view of the assembled electric thermal conduit as taken along the lines B-B in FIG. 7, according to one or more embodiments.

FIG. 10 is schematic front view of another example of the pressure vessel of FIG. 1, according to one or more additional embodiments of the disclosure.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

Unless otherwise defined, all design features and descriptive terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to, which this disclosure pertains. Descriptive terms such as front, top, back, side, bottom, cross-section, perspective, three-dimensional and partial view, or section all pertain to the relevant drawing and figure subject views and direct line of sight.

The present disclosure is generally directed to pressure vessels in the oil and gas industry and, more particularly, to a thermal generation system arranged within a pressure vessel to increase a temperature of a fluidized catalyst and/or particle (i.e., particulate) stream.

The embodiments disclosed herein describe thermal generation systems configured to transfer electrically-generated thermal energy to suspended (entrained) catalyst and/or particles within a given pressure vessel. Operating the system affects the process temperature of unattached particles, which is desirable for achieving petrochemical reactions within the pressure vessel. As described herein, the endothermic reaction of the direct catalyst and/or particle is impacted through a plurality of electric-resistance thermal conduits that are self-contained within the architecture of the system. These thermal conduits operate in a process environment between the range of about 1,000° F. (538° C.) to about 2,500° F. (1371° C.). The electric service (i.e., electrical power) provided to the apparatus can be either alternating current (AC) or direct current (DC), and the electric circuit of the system is completely isolated from the metallic components of the pressure vessel.

The embodiments described herein overcome the challenges posed by commercially-known pressure vessel heating systems by providing a method that can function at an operating temperature range between about 1,000° F. (538° C.) and about 2,500° F. (1371° C.), or even more. The electric thermal conduits of the disclosed system are arranged in parallel style columns (referred to herein as “an electric thermal bundle”) that simplifies the mechanical support architecture for the system. The electric thermal conduits are both mechanically and electrically connected. In particular, the electric thermal bundle mechanically supports a given series of thermal conduits, which are pressure sealed in a single apparatus. Moreover, the electric thermal bundle also ensures electric conductivity to each individual thermal conduit, while isolating the electric current from the metallic pressure vessel and supporting architecture. Providing and/or arranging the electric thermal conduits in this manner takes advantage of collectively grouping the conductivity to each thermal conduit in the series.

Advantageously, the electric thermal bundle may be duplicated in series or in parallel rows with additional electric thermal bundles that extend across the cross-sectional area of the pressure vessel. The multiple electric thermal bundles may be configured to cooperatively heat the fluidized catalyst and/or particles within the pressure vessel. Moreover, the plurality of electric thermal bundles can be configured in any quantity in either the horizontal or vertical planes, as required by design. The described system can be duplicated in kind along the axial length of a given vertical pressure vessel.

As used herein, the term “catalyst” refers to a micro sized particle that promotes a chemical reaction to accelerate the rate at which a chemical reaction reaches equilibrium.

As used herein, the term “particle” refers to a micro sized object.

As used herein, the term “fluidized” refers to a method of suspending a micro sized object (e.g., catalyst or particles) in a fluid-like state.

As used herein, the term “thermal” or “thermally” refers to imparting heat energy to an object.

As used herein, the term “distribution bus bar” refers to a metallic structure and method of distributing an electric current onto a series of conductivity locations, which emanated from a single location, and further collecting an electric current from a series of conductivity locations and directing it to a single location.

As used herein, the term “conduit” refers to a electrically-conductive item that can generate a thermal effect. In some contexts, the conduit comprises a solid rod made of a metal, but could alternatively be made of a non-metallic material such as silicon carbide (SiC), graphite, or quartz.

As used herein, the term “bundle” refers to a group of similar objects that function in unison.

As used herein, the term “conductivity” refers to a method of transferring an uninterrupted electric path.

As used herein, the term “petrochemical” refers to a chemical product obtained by processing petroleum and/or natural gas or their derivatives.

As used herein the term “electrical communication,” “electrically coupled,” or any variation thereof refers to placing or having two components in communication such that electrical power or energy is able to be transferred between the two components. As a non-limiting example, an electrical communication can be created with a “jumper”. “Jumper” refers to a mechanical device that is permanently or otherwise attached between adjacent unattached components for the purpose of completing electric conductivity. Electrical communication does not have to be established by permanent means.

FIG. 1 is a schematic front view of an example pressure vessel 102 that may incorporate one or more principles of the present disclosure. As illustrated, the interior of the pressure vessel may be lined or otherwise covered with an insulation barrier 104. The insulation barrier 104 may comprise, for example, a refractory material anchored or otherwise secured to the inner wall of the pressure vessel 102 via any known anchoring or attachment method. Suitable materials for the refractory material include, but are not limited to, silicon carbide, magnesia, alumina, alumina graphite, magnesia graphite, high temperature porcelain, zirconia, zirconia ceramic, alumino-silicate, silica, carbon/graphite (e.g., graphite, crystalline and amorphous carbon), silicon nitride, spinel, or any combination thereof.

The pressure vessel 102 may be configured to receive a particulate stream 106 via a first or “inlet” port 108a. The particulate stream 106 may comprise particles, a catalyst, a combination of a fluid and particles, and any combination thereof. In some applications, the particulate stream 106 may or may not be fluidized prior to entering the vessel. After fluidization and processing (heating), a heated fluidized particulate stream 106 may be discharged from the pressure vessel 102 at discharge port 108b. The pressure vessel 102 may further include a gas manifold or “distributor” 110 configured to introduce a fluid (e.g., a gas and/or a liquid, such as in an atomized state) into the pressure vessel 102 and thereby provide a uniform gas distribution system that fluidizes the entrained particulate stream 106 within the pressure vessel 102. In alternative embodiments, the particulate stream 106 may be replaced with a generally “fluid” stream. In such embodiments, the fluid stream may comprise a gas, a liquid, or a mixture thereof with no particles. Moreover, in such embodiments, the principles of the present disclosure would work equally the same.

According to embodiments of the present disclosure, the pressure vessel 102 may house and otherwise contain a thermal generation system 111 operable to provide thermal energy to the entrained fluidized particulate stream 106 as it flows through (within) the pressure vessel 102. As illustrated, the thermal generation system (hereafter “the system 111”) may include one or more electric thermal bundles 112 (one shown) arranged within the pressure vessel 102. As described in more detail below, while only one electric thermal bundle 112 is shown in FIG. 1, the system 111 may include two or more electric thermal bundles 112 arranged in series or in parallel, without departing from the scope of the disclosure.

The electric thermal bundle 112 may include a plurality of spaced-apart, electric thermal conduits 114 that extend substantially vertical within the pressure vessel 102. A rectangular or elongated brace 116 uniformly joins the lower end of each electric thermal conduit 114 in series and in a common horizontal plane. In operation, the electric thermal conduits 114 generate and radiate thermal energy (e.g., heat) into the interior of the pressure vessel 102. While a specific number of electric thermal conduits 114 are shown in FIG. 1, the number of electric thermal conduits 114 used in the electric thermal bundle 112 may be more or less than what is depicted, without departing from the scope of the disclosure.

The electric thermal bundle 112 may be powered and otherwise receive electrical power or “input electric service” 118 (i.e., electricity for operation) via a vessel nozzle 120 coupled to the outer wall of the pressure vessel 102. At least a portion of the vessel nozzle 120 may penetrate the wall(s) of the pressure vessel 102 and extend a short distance into the interior to enable the input electric service 118 to reach the electric thermal bundle 112. The input electric service 118 may comprise alternating current (AC) or direct current (DC). As described in more detail below, the input electric service 118 may electrically communicate with a first distribution bus bar 122 attached to and in electrical communication with the series of electric thermal conduits 114, and thereby convey electrical power to the electric thermal conduits 114 during operation.

FIG. 2 is a schematic top, cross-sectional view of the system 111, according to one or more embodiments. As illustrated, the system 111 may include a plurality of electric thermal bundles 112 arranged within the pressure vessel 102 and substantially surrounded by the thermal barrier 104. The electric thermal bundles 112 may be laterally offset from each other a short distance and, in some embodiments, some or all of the laterally-offset electric thermal bundles 112 may extend in substantially parallel and vertical planes within the interior of the pressure vessel 102.

Each electric thermal bundle 112 may include a plurality of laterally spaced-apart electric thermal conduits 114 extending vertically from a corresponding first distribution bus bar 122. Moreover, each electric thermal bundle 112 is provided input electric service 118 via a dedicated vessel nozzle 120. A return path 202 for the input electric service 118 may also be provided at the dedicated vessel nozzle 120, and each return path 202, which also extends through the vessel nozzle 120. As discussed in more detail below, the return path 202 for each electric thermal bundle 112 may be electrically coupled to a second distribution bus bar 204, which may provide electric continuity between the electric thermal conduits 114 and the return path 202.

While FIG. 2 depicts a specific number of electric thermal bundles 112 arranged in parallel and forming part of the system 111, more or less may be employed, without departing from the scope of the disclosure. Moreover, as illustrated, the electric thermal bundles 112 may include varying numbers of electric thermal conduits 114. In some embodiments, for example, the electric thermal bundles 112 arranged closer to the centerline (e.g., longitudinal, vertical axis) of the pressure vessel 102 may include more electric thermal conduits 114 as compared to the electric thermal bundles 112 that are arranged further from the centerline.

FIG. 3 is another schematic cross-sectional side view of the pressure vessel 102, according to one or more additional embodiments. The view in FIG. 3 is angularly offset from the view in FIG. 1 by 90 degrees. Accordingly, a plurality of electric thermal bundles 112 forming part of the system 111 are illustrated as arranged vertically within the pressure vessel 102 and laterally offset from each other. In some embodiments, as mentioned above, the electric thermal bundles 112 may extend in substantially parallel vertical planes. Moreover, the specific number of electric thermal bundles 112 forming part of the system 111 is not limited to what is shown in FIG. 3, but may instead include more or less electric thermal bundles 112, without departing from the scope of the disclosure.

As illustrated, a thermally cool stream (i.e., cooler than the temperature leaving the pressure vessel 102) of the particulate stream 106 enters the pressure vessel 102 through the inlet port 108a. A stream of gas 302 (or an atomized liquid) may be simultaneously injected into the interior of the pressure vessel 102 via the gas manifold 110. The gas manifold 110 may be in fluid communication with an inlet gas nozzle 304 coupled to the outer wall of the pressure vessel 102. A portion of the inlet gas nozzle 304 penetrates the wall(s) of the pressure vessel 102 and extends a short distance into the interior to fluidly communicate with the gas manifold 110. The gas manifold 110 may provide or otherwise define a plurality of orifices through which the gas 302 may be discharged from the gas manifold 110 and into the interior of the pressure vessel 102.

Injecting the gas 302 into the pressure vessel 102 may help suspend and entrain the inventory of catalyst and/or particles included in the fluidized particulate stream 106 generally within an area D1 defined within the pressure vessel 102. In some embodiments, the pressure of the gas 302 injected into the pressure vessel 102 may be adjusted and otherwise optimized to establish a mean matter level 306 for the particulate stream 106. By using a base level of injection of the gas 302, the particulates 106 within the area D1 may be converted into a fluidized state, thereby resulting in a maximized concentration 308 of unattached particulates 106. As illustrated, the system 111, including the array of electric thermal bundles 112, may be substantially located below the mean matter level 306 and within the area D1, where the maximized concentration 308 of the fluidized particulates 106 may be present, thereby helping promote desired heat transfer. In some applications, the fluidized bed of the particulates 106 can operate just above minimum fluidization or in a bubbling regime, which capitalizes on a difference in density between the gas 302 and the particulates 106, which promotes the whole system to behave like a liquid.

As the gas 302 is injected into the pressure vessel 102, the fluidized particulates 106 may be caused to remain generally within the area DI and otherwise in proximity to the system 111 in a fluidized and dynamic state. With the electric thermal bundles 112 operating and generating thermal energy, the generated thermal energy may radiate from the thermal conduits 114 and the suspended residence time within the area DI will increase the temperature of the fluidized particulates 106. The suspended fluidized particulates 106 will eventually fall below the area D1 within the pressure vessel 102 and may be discharged as a hot fluidized particulate stream 106 through the discharge port 108b.

FIGS. 4A and 4B are enlarged, schematic front and top views, respectively, of an example electric thermal bundle 112, according to one or more embodiments. As illustrated, the electric thermal bundle 112 may be attached to and supported by the pressure vessel 102, including the thermal barrier 104, at locations 403a and 403b. The locations 403a and 403b comprise angularly offset sidewall portions within the interior of the pressure vessel 102 where the opposing axial ends of the electric thermal bundle 112 may be secured. In some embodiments, the locations 403a and 403b may comprise angularly opposite sides of the pressure vessel 102. As best seen in FIG. 4A, one or more mechanical fasteners 404, such as nut and bolt fasteners, may be used to secure the electric thermal bundle 112 in place on the pressure vessel 102 at the locations 403a and 403b.

In some embodiments, the plurality of electric thermal conduits 114 may be welded or otherwise secured to a support member 402 (FIG. 4A) and extend distally (vertically downward) therefrom. In such embodiments, opposing ends of the support member 402 may be secured to angularly offset sidewall portions of the pressure vessel 102 at the locations 403a and 403b. In at least one embodiment, as illustrated, the electric thermal conduits 114 may extend substantially parallel to one another, but one or more electric thermal conduits 114 may alternatively extend at an angle (e.g., offset from parallel) relative to an adjacent electric thermal conduit 114.

As mentioned above, electrical power (energy) is provided to the electric thermal conduits 114 via the first distribution bus bar 122, which may be operatively coupled to the support member 402. In some embodiments, the first distribution bus bar 122 may include an input bus bar 408 that extends from the input electric service 118. In particular, in at least one embodiment, the input bus bar 408 may form an integral extension of the first distribution bus bar 122. In other embodiments, however, the input bus bar 408 may be welded (e.g., lap welded) to the first distribution bus bar 122, but could alternatively be secured to the first distribution bus bar 122 with one or more mechanical fasteners that facilitate electrical communication. As best seen in FIG. 4A, the input bus bar 408 may be arranged within a cylindrical liner 410 (e.g., concentrically), which is positioned within or forms part of the vessel nozzle 120. Those of ordinary skill in the art will understand that the input and output bus bar facilitate either DC or AC current without departing from the arranged components as described herein for the exemplary embodiments.

Electric continuity between the first distribution bus bar 122 and the electric thermal conduits 114 may be accomplished by welding to a power input electrode of each electric thermal conduit 114, as discussed in more detail below. As best seen in FIG. 4B, the electric thermal bundle 112 may further include the second distribution bus bar 204, which may provide electric continuity to the electric thermal conduits 114 by welding to a power output electrode of each electric thermal conduit 114. The second distribution bus bar 204 may include an output or “secondary” bus bar 412. In some embodiments, the output bus bar 412 may form an integral extension of the second distribution bus bar 204. In other embodiments, however, the output bus bar 412 may comprise any device or mechanism capable of transferring electrical power from the second distribution bus bar 204 to the return path 202. In such embodiments, the output bus bar 412 may comprise, for example, a metallic wire, conduit, or bar welded (e.g., lap welded) to the second distribution bus bar 204, but could alternatively be secured to the second distribution bus bar 204 with one or more mechanical fasteners. A return electrical signal may be conveyed to the return path 202 via the electrical interconnection between the second distribution bus bar 204 and the output bus bar 412.

The first and second distribution bus bars 122, 204 may be enclosed on all sides with a metallic cover 414, and a service access cover 416 may enclose the electrical connection between the input bus bar 408 and the first distribution bus bar 122 and the electrical connection between the output bus bar 412 and the second distribution bus bar 204. As its name suggests, the service access cover 416 may provide a location for a user to access and service (if needed) the electrical connection between the input and output bus bars 408, 412 and the distribution bus bars 122, 204, respectively.

FIG. 5 is an enlarged cross-sectional front view of an example of the vessel nozzle 120, according to one or more embodiments of the disclosure. As illustrated, the input bus bar 408 extends within the cylindrical liner 410, and the input electric service 118 is electrically coupled thereto to provide electrical power to the system 111 (FIGS. 1-3). In the illustrated embodiment, the input bus bar 408 is depicted as a metallic bar. As indicated above, however, the input bus bar 408 may form part of the distribution bus bar 408, either as an integral extension thereof or a separate component part attached thereto.

As illustrated, the vessel nozzle 120 must include an isolation assembly 502 that incorporates a first isolation barrier 504 operable to isolate the electric current flowing through the input electric service 118 from contacting metallic surfaces of the vessel nozzle 120. In some embodiments, the isolation assembly 502 is made of metal and secured to the vessel nozzle 120 with a circumferential seal weld 506, which serves to provide a pressurized seal.

The first isolation barrier 504 may be integral with the isolation assembly 502 and may extend a short distance into an inner channel 510 of the vessel nozzle 120. The first isolation barrier 504 may be made of a variety of non-metallic or non-conductive materials. In at least one embodiment, for example, the isolation barrier 504 may be made of a hardened or hard-surfaced material, such as a ceramic or a ceramic composition that will not conduct electric current, but can withstand the high temperature generated from the electric current.

The vessel nozzle 120 may further include a second isolation barrier 508 arranged within the inner channel 510. The second isolation barrier 508 may be configured to maintain an internal concentric assembly of all integrated components within the inner channel 510, such as the input bus bar 408 (and the output bus bar 412, not shown). The second isolation barrier 508 may be made of similar materials as the first isolation barrier 504, and therefore will not conduct electric current, but can withstand the high temperature generated from the electric current.

The vessel nozzle 120 may further include or otherwise define a pressurized gas inlet port 512a and a pressurized gas outlet port 512b. The inlet port 512a provides a location for injecting a pressurized gas stream 514 into the inner channel 510 of the vessel nozzle 120, which conveys the pressurized gas stream 514 into a fluidly coupled electric thermal bundle 112 (FIG. 4). The gas outlet port 512b may provide a location for controlling the discharge of the pressurized gas stream 514 from the electric thermal bundle 112. Injecting the pressurized gas stream 514 into the electric thermal bundle 112 may prove advantageous in providing insulation to the individual elements (e.g., using the dielelectric strength of the gas) and to provide an oxide layer to the heating elements, which can be critical to good radiant heat transfer to the sheath/outer tube. Injecting the pressurized gas stream 514 into the electric thermal bundle 112 may also prove advantageous in helping to monitor for leaks in the metallic cover 414 (FIG. 4) and/or service access cover 416 (FIG. 4). In particular, a pressure sensor (not shown) or the like may be included at the gas outlet port 512b and may monitor the discharge of the pressurized gas stream 514 from the electric thermal bundle 112. If the outgoing fluid pressure differs from the incoming fluid pressure at the gas inlet port 512a, that may be an indication of the pressurized gas 514 leaking into the interior of the pressure vessel 102. In other applications, or in addition thereto, injecting the pressurized gas stream 514 into the electric thermal bundle 112 may prevent the migration of the fluidized particulate stream 106 (FIG. 3) into the electric thermal bundle 112.

FIG. 6 is an enlarged, cross-sectional end view of the upper and lower portions of the electric thermal bundle 112 of FIGS. 4A and 4B, according to one or more embodiments. As illustrated, the input bus bar 408 may be welded (e.g., lap welded) at junction 602 to the first distribution bus bar 122 and further welded to a first continuity component 604 at junction 606. The first continuity component 604 may be made of an electrically-conductive material, such as a metal, a metal alloy, graphite, or an electrically-conductive ceramic. Moreover, the first continuity component 604 may be made of the same or a different material as the first distribution bus bar 122. The first continuity component 604 may be further welded to a power input electrode 608 of each thermal conduit 114 at corresponding junctions 610. One or more upper or “first-tier” power continuity jumpers 612 (one shown) may be arranged to transfer electric continuity to a power output electrode 614 of each thermal conduit 114. The power output electrode 614 may be welded (e.g., lap welded) in similar fashion to a second continuity component 616, which may be welded to the second distribution bus bar 204 and further welded to the output bus bar 412. Similar to the first continuity component 604, the second continuity component 616 may be made of an electrically-conductive material, such as a metal, a metal alloy, graphite, or an electrically-conductive ceramic, and may further be made of the same or a different material as the second distribution bus bar 204.

The function of the input and output electrodes 608, 614 is to produce heat when an electric current is applied through the continuity circuit. In some embodiments, the power input and output electrodes 608, 614 may comprise solid rods of an electrically-conductive material. The input and output electrodes 608, 614 may exhibit a diameter between about 0.06 inches to about 1.00 inch. A diameter between about 0.125 inches to about 0.75 inches may be preferred, and a diameter between about 0.3 inches and about 0.5 inches may be most preferred. In some embodiments, the length of the input and output electrodes 608, 614 may be at least 300 times greater than their diameter.

The input and output electrodes 608, 614 may be housed within a cylindrical housing 618 with a substantially circular cross-section. In some embodiments, the axial length of the housing 618 may be at least 5% longer than the axial length of the input and output electrodes 608, 614. The housing 618 is made of any material that can adsorb and store heat emitted from the input and output electrodes 608, 614. The housing 618, however, is not limited to a circular cross-section, but can instead exhibit a polygonal cross-section, which may provide a denser distribution of thermal conduits 114.

The axial center of the housing 618 for the thermal conduit 114 may include or otherwise incorporate an elongated support member 620 extending axially within the housing 618. In some embodiments, the axial length of the support member 620 may be at least 5% longer than the axial length of the input and output electrodes 608, 614. A plurality of nonmetallic (non-conductive) spacers 622 may be configured to provide a robust means of aligning the input and output electrodes 608, 614 within the housing 618 so that they are ideally spaced from each other and around the circumference (outer periphery) of the support member 620. The support member 620 may be fixed to the housing 618 with a plurality of support arms 624 at weld locations 626a and 626b. The support arms 624 may be positioned between the input and output electrodes 608, 614 to avoid an electric fault and/or electric short.

The support member 620 may terminate with a fixed guide 628 at the lowest internal location within the housing 618. The fixed guide 628 may help facilitate a concentric alignment of the internal assembly of the thermal conduit 114 as the internal assembly moves radially and axially due to thermal expansion and contraction. The housing 618 may terminate with a similarly-shaped termination plate 630, which may be circumferentially seal welded to the end of the housing 618 at location 632. The termination plate 630 is further joined to the elongated brace 116, which uniformly joins all similar electric thermal bundle 112 assemblies in the same projected horizontal plane.

The internal components of the electric thermal bundle 112 may be fully enclosed within the metallic cover 414 and the housing 618. The metallic cover 414 may be seal welded to a support plate 634 at junction 636, and the housing 618 may be attached to the longitudinal support member 402 with a circumferential seal weld 638. This generates a substantially sealed interior to each electric thermal bundle that helps prevent catalyst and/or particles from entering (migrating into) the enclosure.

FIG. 7 is a cross-sectional side view of the entire assembled electric thermal bundle 112 of FIG. 6, according to one or more embodiments. The overall length L1 of the electric thermal bundle 112 can be fabricated (designed) to suit the thermal output requirement. The length L1 extends from the service access cover 416 to the termination plate 630. The nonmetallic spacers 622 that are integral to the support member 620 may be arranged in a reasonable quantity in proportion to the overall length L1 of the electric thermal bundle 112, and as directed by the calculus results of an analytical analysis. The side cross-section view indicates the location of the upper continuity jumper 612 and one or more lower or “second-tier” continuity jumpers 702 with respect to the terminating ends of the housing 618.

FIG. 8 is a cross-sectional top view of the assembled electric thermal conduit 114 as taken along the lines A-A in FIG. 7, according to one or more embodiments. In particular, FIG. 8 depicts an upper end or portion of the assembled electric thermal conduit 114. The cylindrical housing 618 contains an array of heat producing input and output electrodes 608, 614. The input electrode 608 inputs electric power to the thermal conduit 114 at the highest axial location of the cylindrical housing 618. The electric continuity circuit path of each electrode 608, 614 is horizontally connected with a series of conductive (e.g., like material) upper continuity jumpers 612 that are equally sized in cross-sectional area as the electrodes 608, 614. In particular, the surface area encompassed by the physical connection between 608, 614 and the upper continuity jumper 612 has the same cross-sectional area. The assembled array of more than two input and output electrodes 608, 614 and corresponding upper continuity jumpers 612 are circumferentially positioned around the support member 620. The output electrode 614 serves as the electric service output.

FIG. 9 is a cross-sectional top view of the assembled electric thermal conduit 114 as taken along the lines B-B in FIG. 7, according to one or more embodiments. In particular, FIG. 9 depicts a lower end or portion of the assembled electric thermal conduit 114. As illustrated, the cylindrical housing 618 contains an array of the heat-producing input and output electrodes 608, 614. The input and output electrodes 608, 614 may be configured to transfer electric power from the highest axial location to the lowest axial location of the cylindrical housing 618. The electric continuity circuit path of each electrode 608, 614 is horizontally connected with a series of conductive (e.g., like material) lower continuity jumpers 702 that are equally sized in cross-sectional area as the electrodes 608, 614. In particular, the surface area encompassed by the physical connection between 608, 614 and the lower continuity jumper 702 has the same cross-sectional area. The assembled array of a plurality of the input and output electrodes 608, 614 and lower continuity jumpers 702 are circumferentially positioned around the support member 620. The input electrode 608 serves as the electric service input, and the output electrode 614 serves as the electric service output.

FIG. 10 is schematic front view of another example of the pressure vessel 102, according to one or more embodiments of the disclosure. As illustrated, the pressure vessel 102 may be lined with the thermal barrier 104 and may house a thermal generation system 111 that includes a plurality of electric thermal bundles 112 vertically offset from each other within the interior of the pressure vessel 102. While three electric thermal bundles 112 are depicted, more or less than three electric thermal bundle 112 may be included in the system 111, without departing from the scope of the disclosure.

The entrained particulate stream 106 may enter the pressure vessel 102 through the inlet port 108a, and subsequently be discharged from the pressure vessel 102 via the discharge port 108b. Each electric thermal bundle 112 may include a plurality of spaced electric thermal conduits 114, and electrical power or “electric service” 118 for each electric thermal bundle 112 may pass through a corresponding vessel nozzle 120 attached to the outer wall of the pressure vessel 102. The gas manifold 110 may be arranged below the electric thermal bundles 112 and configured to inject a fluid (e.g., a gas or atomized liquid) into the pressure vessel 102 and thereby provide a gas distribution system that fluidizes and entrains the particulate stream 106 within the pressure vessel 102 and thereby generates a fluidized particulate stream 106, as generally described above.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the present specification and associated claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the incarnations of the present inventions. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claim, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

One or more illustrative incarnations incorporating one or more invention elements are presented herein. Not all features of a physical implementation are described or shown in this application for the sake of clarity. It is understood that in the development of a physical embodiment incorporating one or more elements of the present invention, numerous implementation-specific decisions must be made to achieve the developer's goals, such as compliance with system-related, business-related, government-related and other constraints, which vary by implementation and from time to time. While a developer's efforts might be time-consuming, such efforts would be, nevertheless, a routine undertaking for those of ordinary skill in the art and having benefit of this disclosure.

Additional Embodiments

Embodiment 1: A pressure vessel includes an inlet port through which a particulate stream is introduced into an interior of the pressure vessel, a discharge port through which a heated fluidized particulate stream is discharged from the interior of the pressure vessel, and a thermal generation system arranged within the interior of the pressure vessel and operable to increase a temperature of the fluidized particulate stream and thereby produce the heated fluidized particulate stream. The thermal generation system includes one or more electric thermal bundles, and each electric thermal bundle includes a plurality of spaced-apart, electric thermal conduits arranged in series and extending substantially vertical within the pressure vessel, each electric thermal conduit being operable to generate and radiate thermal energy into the interior of the pressure vessel, a distribution bus bar electrically coupled to each electric thermal conduit, and a receiving bus bar electrically coupled to each electric thermal conduit to complete the circuit.

Embodiment 2: The pressure vessel of Embodiment 1, further comprising a gas manifold arranged within the interior and operable to inject a fluid into the pressure vessel to fluidize the fluidized particulate stream.

Embodiment 3: The pressure vessel of Embodiment 1 or 2, further comprising a vessel nozzle coupled to an outer wall of the pressure vessel and through which the input electric service and the return path are communicated to the distribution and receiving bus bars, respectively.

Embodiment 4: The pressure vessel of Embodiment 3, further comprising an input bus bar extending through the vessel nozzle and placing the distribution bus bar in electrical communication with the input electric service, and an output bus bar extending through the vessel nozzle and placing the receiving bus bar in electrical communication with the return path.

Embodiment 5: The pressure vessel of Embodiment 4, wherein the input and output bus bars are arranged within a cylindrical liner positioned within the vessel nozzle.

Embodiment 6: The pressure vessel of Embodiment 4, further comprising one or more isolation barriers arranged within an inner channel of the vessel nozzle and operable to isolate electric current flowing through the input electric service and the return path from contacting metallic surfaces of the vessel nozzle.

Embodiment 7: The pressure vessel of Embodiment 3, wherein the vessel nozzle includes a gas inlet port providing a location for the injection of a pressurized gas stream into a fluidly coupled electric thermal bundle, the pressurized gas stream being operable to prevent migration of the fluidized particulate stream into the fluidly coupled electric thermal bundle, and a gas outlet port providing a location for the controlled discharge of the pressurized gas stream from the fluidly coupled electric thermal bundle.

Embodiment 8: The pressure vessel of any of Embodiments 1-7, wherein the one or more electric thermal bundles comprise a plurality of electric thermal bundles arranged within the interior of the pressure vessel and laterally-offset from each other, each electric thermal bundle extending in substantially parallel and vertical planes within the interior.

Embodiment 9: The pressure vessel of any of Embodiments 1-8, wherein opposing ends of each electric thermal bundle are supported by the pressure vessel at angularly offset sidewall locations within the interior of the pressure vessel.

Embodiment 10: The pressure vessel of Embodiment 9, wherein each electric thermal bundle includes a support member and opposing ends of the support member are secured to the angularly offset sidewall portions, the plurality of electric thermal conduits being secured to the support member and extending vertically downward therefrom.

Embodiment 11: The pressure vessel of any of Embodiments 1-10, wherein the distribution bus bar is welded to a power input electrode of each electric thermal conduit, and the receiving bus bar is welded to a power output electrode of each electric thermal conduit, and wherein each electric thermal conduit further includes one or more power continuity jumpers extending between and electrically coupling angularly adjacent power input and output electrodes.

Embodiment 12: The pressure vessel of Embodiment 11, wherein one or both of the power input and output electrodes comprise a solid rod made of an electrically-conductive material and exhibiting a diameter between about 0.06 inches and about 1.00 inch.

Embodiment 13: The pressure vessel of Embodiment 11, wherein each electric thermal conduit further includes a cylindrical housing in which the power input and output electrodes are housed, and an elongate support member extending vertically within the cylindrical housing and fixed to the cylindrical housing with a plurality of support arms.

Embodiment 14: The pressure vessel of Embodiment 13, wherein each electric thermal conduit further includes a fixed guide attached to an end of the support member to help facilitate a concentric alignment of the power input and output electrodes within the cylindrical housing during thermal expansion and contraction.

Embodiment 15: The pressure vessel of any of Embodiments 1-14, wherein the thermal generation system is a first thermal generation system and the pressure vessel further includes a second thermal generation system arranged within the interior of the pressure vessel and vertically offset from the first thermal generation system.

Embodiment 16: The pressure vessel of any of Embodiments 1-15, wherein each electric thermal bundle further includes an elongated brace secured to a lower end of each electric thermal conduit and thereby aligning the lower end of each electric thermal conduit in a common horizontal plane.

Embodiment 17: A method of heating a particulate stream includes introducing the particulate stream into an interior of a pressure vessel via an inlet port, fluidizing the particulate stream and thereby generating a fluidized particulate stream, and increasing a temperature of the fluidized particulate stream with a thermal generation system and thereby producing a heated fluidized particulate stream. The thermal generation system may be arranged within the interior of the pressure vessel and may include one or more electric thermal bundles. Each electric thermal bundle may include a plurality of spaced-apart, electric thermal conduits arranged in series and extending substantially vertical within the pressure vessel, each electric thermal conduit being operable to generate and radiate thermal energy into the interior of the pressure vessel, a distribution bus bar electrically coupled to each electric thermal conduit to provide input electric service to each electric thermal conduit, a receiving bus bar electrically coupled to each electric thermal conduit to provide a return path for the input electric service, and an elongate brace secured to a lower end of each electric thermal conduit and thereby aligning the lower end of each electric thermal conduit in a common horizontal plane. The method may further include discharging the heated fluidized particulate stream from the interior of the pressure vessel via a discharge port.

Embodiment 18: The method of Embodiment 17, further comprising injecting a fluid into the pressure vessel with a gas manifold arranged within the interior and thereby fluidizing the fluidized particulate stream, and adjusting a pressure of the fluid discharged from the gas manifold and thereby suspending and entraining the fluidized particulate stream within an area defined within the pressure vessel where the thermal generation system is located.

Embodiment 19: The method of Embodiment 17 or 18, further comprising communicating the input electric service and the return path to the distribution and receiving bus bars, respectively, through a vessel nozzle coupled to an outer wall of the pressure vessel.

Embodiment 20: The method of Embodiment 19, further comprising injecting a pressurized gas stream into a fluidly coupled electric thermal bundle via a gas inlet port provided on the vessel nozzle, preventing migration of the fluidized particulate stream into the fluidly coupled electric thermal bundle with the pressurized gas stream, and discharging the pressurized gas stream from the fluidly coupled electric thermal bundle via a gas outlet port provided on the vessel nozzle.

Embodiment 21: The method of any of Embodiments 17-20, further comprising providing the input electric service to each thermal conduit via the distribution bus bar welded to a power input electrode of each electric thermal conduit, providing the return path for the input electric service to each thermal conduit via the receiving bus bar welded to a power output electrode of each electric thermal conduit, and electrically coupling angularly adjacent power input and output electrodes with one or more power continuity jumpers.

Embodiment 22: A pressure vessel includes an inlet port through which a fluid stream is introduced into an interior of the pressure vessel and fluidized, a discharge port through which a heated fluid stream is discharged from the interior of the pressure vessel, and a thermal generation system arranged within the interior of the pressure vessel and operable to increase a temperature of the fluid stream and thereby produce the heated fluid stream, the thermal generation system including one or more electric thermal bundles. Each electric thermal bundle includes a plurality of spaced-apart, electric thermal conduits arranged in series and extending substantially vertical within the pressure vessel, each electric thermal conduit being operable to generate and radiate thermal energy into the interior of the pressure vessel, a distribution bus bar electrically coupled to each electric thermal conduit to provide input electric service to each electric thermal conduit, and a receiving bus bar electrically coupled to each electric thermal conduit to provide a return path for the input electric service.

Embodiment 23: The pressure vessel of Embodiment 22, wherein the fluid stream comprises a gas, a liquid, or a combination of the gas and the liquid, and void of particles.

Therefore, the present invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular examples and configurations disclosed above are illustrative only, as the present invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative examples disclosed above may be altered, combined, or modified and all such variations are considered within the scope and spirit of the present invention. The invention illustratively disclosed herein suitably may be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces.