WO2025043324A1 - Systems and methods for heating a conductive feedstock - Google Patents
Systems and methods for heating a conductive feedstock Download PDFInfo
- Publication number
- WO2025043324A1 WO2025043324A1 PCT/CA2024/051063 CA2024051063W WO2025043324A1 WO 2025043324 A1 WO2025043324 A1 WO 2025043324A1 CA 2024051063 W CA2024051063 W CA 2024051063W WO 2025043324 A1 WO2025043324 A1 WO 2025043324A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- heating
- feedstock
- elongated body
- vertically elongated
- heating stage
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F26—DRYING
- F26B—DRYING SOLID MATERIALS OR OBJECTS BY REMOVING LIQUID THEREFROM
- F26B3/00—Drying solid materials or objects by processes involving the application of heat
- F26B3/32—Drying solid materials or objects by processes involving the application of heat by development of heat within the materials or objects to be dried, e.g. by fermentation or other microbiological action
- F26B3/34—Drying solid materials or objects by processes involving the application of heat by development of heat within the materials or objects to be dried, e.g. by fermentation or other microbiological action by using electrical effects
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B3/00—Ohmic-resistance heating
- H05B3/60—Heating arrangements wherein the heating current flows through granular powdered or fluid material, e.g. for salt-bath furnace, electrolytic heating
Definitions
- the described embodiments relate generally to systems and methods for heating, and in particular, systems and methods of heating a conductive feedstock.
- Background [2] In many industrial settings, processed materials may need to be heated. For example, industrial drying involves removing water of a material, such as dehydration or lowering moisture content. Another application can be heating of water in industrial processes, or in commercial buildings. [3] Heating is typically achieved by burning fossil fuels or by applying electrical heating elements to deliver heat by surface transfer to the material. Heating can also be accomplished by electromagnetic radiation, such as in a microwave oven. However, such heating methods can be inefficient, difficult to scale to industrial size, slow, and yield non- uniform heating of the material.
- the system includes at least one heating stage, each heating stage can include at least one pump for pumping the feedstock, a heating chamber comprising a vertically elongated body and a plurality of electrodes coupled to the vertically elongated body, an expansion valve downstream of the vertically elongated body, a separator downstream of the expansion valve, and at least one electrical generator operable to excite the plurality of electrodes.
- the feedstock can include a conductive liquid having an initial temperature and an initial pressure.
- the vertically elongated body can include an upper portion and a lower portion. The lower portion can be configured to receive the pumped feedstock.
- the plurality of electrodes can be operable to apply at least one alternating current to the feedstock within the vertically elongated body to heat the feedstock volumetrically to a saturation temperature while the feedstock remains at the initial pressure.
- the feedstock can be a fluid at the saturation temperature.
- the expansion valve can be operable to reduce a pressure of the fluid from the initial pressure to a lower pressure. The reduction in pressure can cause vapor to flash off from the fluid.
- the separator can be configured to separate the vapor from heated liquid of the fluid.
- the heated liquid can have a residual temperature that is higher than the initial temperature and lower than the saturation temperature.
- the at least one electrical generator can be coupled to one or more intermediate electrodes of the at least one intermediate electrode to control a heating profile of the feedstock within the heating chamber.
- each of the upper electrode and the lower electrode can be grounded.
- the passage within each electrode of the plurality of electrodes can include a plurality of protrusions to increase a surface area of the electrode that is in contact with the feedstock.
- the system can further include a DC current source coupled to the upper electrode to compensate for rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode.
- the upper portion can have a diameter that is smaller than a diameter of the lower portion to increase a velocity of the fluid.
- the expansion valve can include an inlet formed by the upper electrode.
- the expansion valve can further include an outlet adjoined to the separator.
- the separator can include a return orifice configured to allow the heated liquid to return to the at least one pump, thereby reducing electrical current outside of the vertically elongated body.
- the insulation can be formed of an RF- transparent material.
- the plurality of electrodes can include coaxial electrodes.
- the plurality of electrodes can include parallel plate electrodes.
- the plurality of electrodes can be formed of a material that is non-reactive to the alternating current.
- the at least one electrical generator can be operable to adjust one or more of a frequency or a voltage of each alternating current of the at least one alternating current.
- the system can further include a processor operable to adjust the at least one electrical generator based on one or more of a desired heating profile along a length of the vertically elongated body, a cross-sectional area of the vertically elongated body, or a conductivity of the feedstock.
- each electrical generator of the at least one electrical generator can include at least one transformer for generating the at least one alternating current.
- the frequency of the alternating current can be greater than 100 Hz.
- the at least one heat exchanger downstream of the separator can be configured to recover energy from the heated liquid.
- the at least one heating stage can include a plurality of heating stages; and the energy recovered from one heating stage of the plurality of heating stages can be used to pre-heat feedstock of another heating stage of the plurality of heating stages.
- the system can include at least one vacuum system to control the temperature of the feedstock at each heating stage of the at least one heating stage.
- the feedstock can include brine.
- the feedstock can include non-soluble particles.
- the vapor can include steam.
- a method for heating a feedstock in at least one heating stage can involve, for each heating stage of the at least one heating stage: pumping the feedstock into a lower portion of a vertically elongated body, the feedstock including a conductive liquid having an initial temperature and an initial pressure; and applying at least one alternating current to the feedstock within the vertically elongated body to heat the feedstock volumetrically to a saturation temperature while the feedstock remains at the initial pressure.
- the feedstock can be a fluid at the saturation temperature.
- the method can further involve allowing the fluid to exit from an upper portion of the vertically elongated body; after the fluid has exited the vertically elongated body, reducing a pressure of the fluid from the initial pressure to a lower pressure, the reduction in pressure causing vapor to flash off from the fluid; and separating the vapor from heated liquid of the fluid.
- the heated liquid can have a residual temperature that is higher than the initial temperature and lower than the saturation temperature.
- the method can involve, for the one or more heating stages of the at least one heating stage, increasing a velocity of the fluid by configuring the upper portion to have a diameter that is smaller than a diameter of the lower portion.
- the method can involve, for the one or more heating stages of the at least one heating stage, the expansion valve can include an inlet formed by the upper electrode.
- the expansion valve can further include an outlet adjoined to the separator.
- the method can involve reducing electrical current outside of the vertically elongated body by returning the heated liquid to the feedstock to be pumped into the vertically elongated body.
- the method can involve for the one or more heating stages of the at least one heating stage, accelerating the heating of the feedstock by configuring the lower portion to have a diameter that is smaller than a diameter of the upper portion.
- the method can involve, for the one or more heating stages of the at least one heating stage: the vertically elongated body can be formed of an elastic material; and the method can involve operating a toroidal actuator coupled to a portion of the vertically elongated body to adjust a diameter of the portion of the vertically elongated body.
- the method can involve reducing heat loss by providing insulation around at least the vertically elongated body. The insulation can be formed of an RF-transparent material.
- the method can involve, for one or more heating stages of the at least one heating stage, adjusting one or more of a frequency or a voltage of each alternating current of the at least one alternating current.
- adjusting one or more of a frequency or a voltage of each alternating current of the at least one alternating current can be based on one or more of a desired heating profile along a length of the vertically elongated body, a cross- sectional area of the vertically elongated body, or a conductivity of the feedstock.
- the frequency of the alternating current can be greater than 100 Hz.
- the method can involve using one or more of a radio frequency (RF) generator, an alternating current (AC) generator, a microwave generator, or a millimeter wave generator to apply the at least one alternating current to the feedstock.
- RF radio frequency
- AC alternating current
- the method can involve, for one or more heating stages of the at least one heating stage, recovering energy from the fluid to pre-heat the feedstock.
- recovering energy from the fluid can involve recovering energy from the vapor; and the method can involve collecting condensate from cooling the vapor.
- recovering energy from the fluid can involve recovering energy from the heated liquid.
- the at least one heating stage can include a plurality of heating stages; and the method can involve using energy recovered from one heating stage of the plurality of heating stages to pre-heat feedstock of another heating stage of the plurality of heating stages.
- the method involves operating at least one vacuum system to control the temperature of the feedstock at each heating stage of the at least one heating stage.
- the feedstock can include brine.
- the feedstock can include non-soluble particles.
- the vapor can include steam.
- FIG. 1 is a block diagram of example components of an example system for heating a conductive feedstock, in accordance with an example embodiment
- FIG.2A is a diagram of an example pressure change in the system of FIG.1, in accordance with an example embodiment
- FIG.2B is a diagram of another example pressure change in the system of FIG.1, in accordance with another example embodiment
- FIG.3 is an illustration of an example heating chamber for the system of FIG.1, in accordance with an example embodiment
- FIG. 4 is another illustration of the example heating chamber of FIG. 3, in accordance with an example embodiment
- FIG.5 is an illustration of another example heating chamber for the system of FIG. 1, in accordance with an example embodiment
- FIG.6 is an illustration of another example heating chamber for the system of FIG. 1, in accordance with an example embodiment
- FIG.1 is a block diagram of example components of an example system for heating a conductive feedstock, in accordance with an example embodiment
- FIG.2A is a diagram of an example pressure change in the system of FIG.1, in accordance with an
- FIG. 7 is an illustration of a portion of another example heating chamber for the system of FIG.1, in accordance with an example embodiment
- FIG. 8 is an illustration of an example electrode of another example heating chamber for the system of FIG.1, in accordance with an example embodiment
- FIG.9 is an illustration of another example heating chamber for the system of FIG. 1, in accordance with an example embodiment
- FIG. 10A is an electrical representation of an example heating chamber for the system of FIG.1, in accordance with another example embodiment
- FIG.10B is another electrical representation of an example heating chamber for the system of FIG.1, in accordance with another example embodiment
- FIG.11 is an electrical representation of another example heating chamber for the system of FIG.1, in accordance with another example embodiment
- FIG. 12 is an illustration of current crowding occurring in an example heating chamber for the system of FIG.1, in accordance with another example embodiment
- FIG. 13 is an illustration of an example heating chamber with a plurality of electrodes for the system of FIG.1, in accordance with an example embodiment
- FIG. 14 is an illustration of another example heating chamber with a plurality of electrodes for the system of FIG.1, in accordance with an example embodiment
- FIG.15 is an illustration of another example of components of the system of FIG. 1, in accordance with another example embodiment
- FIG. 16 is a diagram of example components of the system of FIG. 1, in accordance with another example embodiment
- FIG. 17 is a diagram of example components of the system of FIG.
- the plurality of electrodes are operable to apply at least one alternating current to the feedstock within the vertically elongated body to heat the feedstock volumetrically to a saturation temperature while the feedstock remains at the initial pressure.
- the feedstock is a fluid at the saturation temperature.
- the expansion valve is operable to reduce a pressure of the fluid from the initial pressure to a lower pressure. The reduction in pressure causes vapor to flash off from the fluid.
- the separator is configured to separate the vapor from heated liquid of the fluid, the heated liquid having a residual temperature that is higher than the initial temperature and lower than the saturation temperature.
- the heating system 100 can include one or more heating stages 130. Each heating stage 130 can include a pump 112, a heating chamber 110, an expansion valve 116, a separator 118, and an electrical generator 120. Although only one heating stage is shown in FIG.1, the system can include additional heating stages.
- the feedstock 102 can be any liquid with increased conductivity.
- the feedstock 102 can be a liquid brine, such as sodium chloride (NaCl), potassium chloride (KCl), or any liquid with electrical conductivity, that is, any liquid having free ions or other electrical loss mechanisms.
- the water may not be de-ionized.
- the feedstock 102 can include different solutes dissolved together.
- the feedstock 102 can include suspended particles that are non-soluble.
- electrically conductive liquids other than water may be used.
- Heating the feedstock 102 can remove or evaporate liquids from the feedstock 102.
- Heating a feedstock 102 containing water can remove at least some of the water content, and thereby dehydrate the feedstock 102.
- Other liquids can also be removed from the feedstock 102.
- Dehydration can occur because ions in the conductive feedstock 102, such as sodium and chloride ions, can be larger and have stronger intermolecular forces compared to water molecules.
- the pump 112 can be any appropriate pump that moves the feedstock to the heating chamber 110.
- pump 112 can be a peristaltic pump.
- the pump 112 can be a cavity progressive pump.
- the feedstock 102 at the output of the pump 112 can have an initial pressure (P i ).
- the initial pressure (P i ) of the feedstock 102 can be above, at, or below the ambient pressure of the feedstock 102.
- the ambient pressure can be atmospheric pressure, such as approximately 100 kPa or 101.3 kPa kPa.
- a heating stage can include additional pumps 112.
- the heating chamber 110 can include a vertically elongated body 114 having an upper portion 114U and a lower portion 114L.
- the vertically elongated body 114 can be provided by a body that is elongated along a longitudinal axis and mounted vertically such that the longitudinal axis is vertical.
- the body 114 can be formed of a non- conductive material.
- the body 114 can be formed of an elastic material.
- the body 114 can be formed of ceramic, glass or composite materials.
- the pressure of the feedstock 102 can become elevated as the feedstock 102 is heated.
- the feedstock 102 is a fluid at the saturation temperature (T s ).
- the feedstock 102 can be an industrial liquid that can be heated to temperatures higher than 100°C.
- the feedstock 102 can be a liquid in food processing where the maximum temperature can be significantly less than 100°C.
- the feedstock fluid can exit the upper portion of the vertically elongated body 114U and pass through the expansion valve 116 downstream of the vertically elongated body 114.
- the expansion valve 116 is operable to reduce the pressure of the feedstock fluid from the initial pressure (P i ) to a lower pressure (P l ).
- the expansion valve 116 can be a variable restriction valve.
- FIG. 2A shown therein is a pressure-enthalpy diagram 200 for water in which pressure is shown on the vertical axis and enthalpy is shown on the horizontal axis.
- Water is a saturated liquid along curve 204 and changes phase to a saturated, or sub-cooled liquid in region 202, that is, to the left of the saturated liquid curve 204.
- Water changes phase to a vapor in region 206, that is, water is superheated to the right of the saturated liquid curve 204.
- the proportion of water that is vapor increases further to the right of the saturated liquid curve 204.
- the proportion of water that is vapor along curve 208a is 10%, 20% along curve 208b, and 30% along curve 208c, etc....
- the expansion valve 116 can reduce the pressure of the fluid along line 210 on FIG. 2A.
- the reduction in pressure can cause vapor to flash off from the fluid.
- the reduction in pressure can cause steam to flash off the fluid.
- 7% of water can be flashed off as steam, in some embodiments.
- the feedstock 102 can be dehydrated.
- the separator 118 is downstream of the expansion valve 116. After passing through the expansion valve 116, the feedstock fluid enters the separator 118.
- the separator 118 is configured to separate the vapor 106 from heated liquid 108 of the fluid.
- the heated liquid 108 has a residual temperature (T r ) that is higher than the initial temperature (Ti) of the feedstock 102 and lower than the saturation temperature (Ts).
- T r residual temperature
- the heated liquid 108 can be recirculated (not shown in FIG.1) within the heating stage 130. That is, the heated liquid 108 can be added to feedstock 102 and returned to pump 112.
- the heated liquid 108 can flow to another heating stage, similar to heating stage 130.
- the heating chamber 110 includes a plurality of electrodes (not shown in FIG.1) coupled to the vertically elongated body 114.
- the electrical generator 120 can be coupled to the plurality of electrodes to excite the plurality of electrodes. Excitation of the plurality of electrodes applies current to the feedstock 102 within the body 114 to heat the feedstock 102 volumetrically.
- the electrical generator 120 can be an alternating current (AC) generator, a radio frequency (RF) generator, a microwave generator, or a millimeter wave generator. Although only one electrical generator 120 is shown in FIG.1, a heating stage 130 can include additional electrical generators 120.
- various components of the heating system 100 are thermally insulated.
- the diameter of the body 314 can be substantially uniform or constant along the length of the body 314. In other embodiments, the diameter of the body 314 can vary along the length of the body 314. In some embodiments, the outer surface of the body 314 can be thermally insulated. [102]
- the heating chamber 310 shown in FIG.3 is shown for illustrative purposes. Other configurations are possible. For example, the dimensions of the body 314 can vary. In some embodiments, the length of the body 314 can be significantly greater than the diameter of the body 314. For example, the body 314 can have a length in the order of approximately 20 times the inner diameter of the body 314.
- the lower electrode 322b can define a passage therein.
- the lower electrode 322b can be a ring or sleeve.
- Feedstock 302 can flow through the passage of the lower electrode 322b and enter the body 314. Within the body 314, the feedstock 302 is heated to the saturation temperature (Ts). At the saturation temperature (T s ), the feedstock is a fluid.
- the upper electrode 322a can define a passage therein as well. Similarly, the upper electrode 322a can be a ring or sleeve.
- the feedstock fluid that is, heated feedstock 302 flows through the passage of the upper electrode 322a and exits the body 314.
- the plurality of electrodes 322 shown in FIG. 3 is shown for illustrative purposes. Other electrode configurations are possible.
- the plurality of electrodes can have a coaxial arrangement. That is, the plurality of electrodes can include an inner electrode and an outer electrode coaxial with the inner electrode, and the body of the heating chamber can be positioned within an annulus formed between the inner electrode and the outer electrode.
- the plurality of electrodes can have a parallel plate arrangement. That is, the plurality of electrodes can include at least a pair of parallel plates and the body of the heating chamber can be sandwiched between the parallel plates.
- the plurality of electrodes can have a helical arrangement.
- the electrical generator 320 can generate an alternating high voltage.
- the waveform and/or the frequency of the output of the electrical generator 320 can be any appropriate waveform and/or frequency.
- the output of the electrical generator 320 can be a sinusoidal waveform with a peak voltage of about 1000 V and a frequency of about 25 kHz. In other embodiments, the output of the electrical generator 320 may not be sinusoidal. In other embodiments, the output of the electrical generator 320 can have a higher frequency, a lower frequency, or include a plurality of frequency components (i.e., broad spectrum signal).
- the electrical conduction can vary depending on the electrical conductivity of the feedstock 302.
- the magnitude of the alternating high voltage applied can depend on the electrical conductivity of the feedstock 302. For example, a higher voltage can be applied when the electrical conductivity of the feedstock 302 is lower. Conversely, a lower voltage can be applied when the electrical conductivity of the feedstock 302 is higher.
- the transfer of heat energy results from the I 2 R dissipation in which I is the current of the electrical generator 320 and R is the equivalent electrical resistance between the upper electrode 322a and the lower electrode 322b.
- the body 314 can be a cylinder having an inner diameter of approximately 1 inch and a length of approximately 23 inches.
- This temperature difference indicates that 32W of enthalpy can be added to every cubic centimeter of feedstock 302.
- the latent heat of vaporization can be approximately 2260 Joules per cubic centimeter at 1 bar.
- the ratio of 400 J/cc to 2260 J/cc means that about 17% of the water can be converted to steam.
- the pressure of the body 314 can be higher than 1 bar. With a higher pressure, the latent heat of vaporization could be even greater.
- the latent heat of vaporization of brine is known to be lower than that of distilled water.
- the presence of ions, such as sodium and chloride ions can disrupt the hydrogen bonding between water molecules and weaken the intermolecular forces, resulting in a lower latent heat of vaporization compared to that of distilled water.
- brine can require less energy to vaporize than pure water.
- FIG. 4 shown therein is another illustration 400 of the example heating chamber 310 of FIG.3.
- the electrical generator 320 applies a current 324 to the feedstock 302 within the body 314.
- the conductivity of the feedstock 302 can be considered substantially same, or uniform, throughout the body 314.
- the temperature of the feedstock 302 at the lower end 408c of the body 314 can be 83°C while the temperature of the feedstock 302 at the upper end 408h of the body 314 can be 115°C.
- the relative temperature difference can remain the same through continued operation after steady state.
- steam bubbles 406 can form near the upper end 408h of the body 314.
- the formation of steam bubbles 406 can depend on the target temperature and the pressure of the heating chamber 310.
- the formation of steam bubbles 406 can expand the specific volume of the feedstock fluid 302.
- the velocity of the feedstock fluid 302 near the upper end 408h of the body 314 can increase.
- the higher velocity can be advantageous as it results in the feedstock fluid 302 being subject to the hotter temperature of the upper end 408h for a shorter time.
- Steam bubbles 406 can also increase local electrical resistance near the upper end 408h of the body 314, resulting in a higher rate of heating.
- the higher rate of heating can be advantageous as the feedstock 302 dwells at the hotter temperature for less time.
- the feedstock 302 can be temperature-sensitive and degrade when exposed to elevated temperatures for a certain duration. For example, many foods, such as proteins, can be temperature-sensitive.
- the feedstock 302 passes through the expansion valve 116, experiences a sudden drop in pressure, and then enters the separator 118. This can release more vapor and quickly cool the feedstock 302. Cooling of the feedstock 302 can also be advantageous as it reduces the time spent at elevated temperatures.
- the conductivity of the feedstock 302 can vary during the heating process. For example, the electrical conductivity of the feedstock 302 can increase with hotter temperatures due to the increased mobility of ions within the feedstock 302.
- the current can increase by a factor of two when the feedstock 302 is heated from about 30°C to 115°C.
- the higher electrical conductivity of the feedstock 302 can offset the greater electrical resistance near the upper end 408h of the body 314 due to steam bubbles 406.
- the shape of the vertically elongated body can be used to shape the heating profile of the feedstock 302 along the length of the heating chamber 310. Referring now to FIG. 5, shown therein is an illustration 500 of another example heating chamber 510 for the heating system 100 of FIG.1, in accordance with an example embodiment.
- the electrical resistance can be a function of the cross-sectional area of the body 514. Further, heat dissipation can also depend on the electrical resistance, as well as the cross-sectional area of the body 514 and the flow rate of the feedstock 502. Hence, heating in different areas along the length of the body 514 can be targeted by adjusting the cross-section of the body 514 along its length, such as but not limited to an axial dimension of the body 514 (e.g., a diameter of a tubular body). For example, more heat can be transferred in the upper portion of the body 514U than the heat transferred in the lower portion of the body 514L.
- the rate of temperature rise in the upper portion of the body 514U can be higher than the rate of temperature rise in the lower portion of the body 514L.
- the higher rate of temperature rise can also additionally increase the velocity of the fluid 502.
- the volume of feedstock 502 that is being heated along a portion of the body 514 can be proportional to the cross-sectional area of that portion of the body 514.
- the volume of feedstock 502 that is being heated along the lower portion of the body 514L is greater than the volume of feedstock 502 that is being heated along the upper portion of the body 514U.
- the overall flow rate along the length of the body 514 can remain constant between the upper portion of the body 514U and the lower portion of the body 514L.
- heating chamber 610 can include a vertically elongated body 614. As shown in FIG.6, expansion valve 616 and separator 618 are integrated with the vertically elongated body 614.
- the body 614 can be formed of a dielectric, non- conductive material. Further, the outer surface of the body 614 can be thermally insulated. Also, the diameter of the upper portion of the body 614 is smaller than the diameter of the lower portion of the body 614.
- the expansion valve 616 is operable to reduce the pressure of the fluid and causes vapor to flash off from the fluid.
- the separator 618 is downstream of the expansion valve 116. As shown in FIG.6, the separator 618 can adjoin the expansion valve 616, in some embodiments. In particular, the outlet of the expansion valve 616 can be coupled to the separator 618. Thus, immediately after the expansion valve 616, the heating chamber 610 widens to the separator 618. The wider cross-section of the separator 618 allows vapor 606 from the fluid to rise.
- the separator 618 includes an upper outlet 618U and a lower outlet 618L.
- the upper outlet 618U can be configured to receive vapor 606 that rises from the fluid. As shown in FIG. 6, the upper outlet 618U can be positioned within the upper portion of the separator 618. Vapor 606 that rises from the fluid can enter the upper outlet 618U.
- the lower outlet 618L can be configured to receive liquid from the fluid. As shown in FIG.6, the lower outlet 618L can be positioned around the lower portion of the separator 618. Heated liquid 608 from the fluid can flow into the lower outlet 618L. Thus, the vapor 606 and the heated liquid 608 can be separated within the separator 618.
- the toroidal actuator 714T can be operated to adjust the diameter of the portion of the body 714 to which it is coupled. That is, the toroidal actuator 714T can compress to constrict the diameter of the body 714 and loosen to not constrict the diameter of the body 714.
- the toroidal actuator 714T can provide a mechanism to control the diameter of the body 714. In some embodiments, the toroidal actuator 714T can be controlled based on the temperature of the feedstock within the body 714. [139]
- the toroidal actuator 714T is shown in FIG.7 for illustrative purposes only. A toroidal actuator 714T can be coupled to other portions of a vertically elongated body 714.
- toroidal actuator 714T can be a lower portion of a vertically elongated body 714.
- the vertically elongated body 714 shown in FIG.7 is shown as being integrated with expansion valve 716 and separator 718.
- a toroidal actuator 714T can be coupled to a vertically elongated body 714 that is not integrated with an expansion valve 716 and a separator 718.
- FIG.8 shown therein is an illustration 800 of an example electrode 822 of another example heating chamber for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to electrodes 322, 622b, electrode 822 can define a passage 826 therein. Feedstock can flow through the passage 826.
- heating chamber 910 can include a vertically elongated body 914 and a plurality of electrodes 922.
- An electrical generator 920 similar to electrical generators 120, 320, 520, 620, can excite the plurality of electrodes 922 to cause conduction and heat the feedstock 502 volumetrically.
- the body 914 can be formed of a dielectric, non-conductive material. Further, the outer surface of the body 914 can be thermally insulated.
- Heating chamber 1010 can include a vertically elongated body 1014 and a plurality of electrodes 1022a, 1022b (herein collectively referred to as the plurality of electrodes 1022). Similar to body 314, the body 1014 can be formed of a dielectric, non-conductive material. Further, the outer surface of the body 1014 can be thermally insulated. As shown in FIG.10A, the body 1014 can be tubular and the diameter of the body 1014 can be substantially uniform or constant along the length of the body 1014, similar to that of 314.
- Electrochemistry can include, but is not limited to, electrolysis of water, which can occur when direct current is applied to the plurality of electrodes 1022. Electrolysis can generate hydrogen and/or oxygen, which is generally undesirable. In some embodiments, gases produced by any electrochemistry, such as hydrogen and oxygen, can be collected from the separator 118. Excitation of the plurality of electrodes 1022 with a frequency in the order of a hundred hertz (Hz) can be sufficient for avoiding electrochemistry. [151] However, the upper electrode 1022a being hotter than the lower electrode 1022b can lead to a difference in the thermionic emission of the plurality of electrodes 1022.
- the difference in thermionic emission can create a weak diode effect, leading to rectification of the alternating current across the upper electrode 1022a.
- An electrical representation 1050 of the heating chamber 1010 with the diode effect (D) is shown in FIG.10B.
- the current can be slightly larger in the forward direction of the diode than the reverse direction of the diode.
- the difference in current can lead to electrochemistry at the plurality of electrodes 1022. Electrochemistry can liberate hydrogen. Electrochemistry can also alter the chemistry of the feedstock.
- the electrical generator can be capacitively coupled, as shown in the electrical representation 1100 of FIG.11, in accordance with an example embodiment.
- Heating chamber 1110 can include a vertically elongated body 1114 and a plurality of electrodes 1122a, 1122b (herein collectively referred to as the plurality of electrodes 1122). Similar to body 314, 1014, the body 1114 can be formed of a dielectric, non-conductive material. Further, the outer surface of the body 1114 can be thermally insulated. As shown in FIG.11, the body 1114 can be tubular and the diameter of the body 1114 can be substantially uniform or constant along the length of the body 1114, similar to that of 314, 1014.
- An electrical generator 1120 similar to electrical generators 120, 320, 520, 620, 920, 1020 can excite the plurality of electrodes 1122 to cause conduction and heat the feedstock within the vertically elongated body 1114 volumetrically.
- a capacitor (C) can be connected in series between the upper electrode 1122a and the electrical generator 1120 and build up a small DC voltage. The capacitor (C) can then self-adapt to the rectification. The capacity of the capacitor (C) can be selected based on the frequency of the excitation applied to the plurality of electrodes. A small-valued capacitor (C) can be sufficient for a fairly high frequency of excitation.
- a DC current source can be coupled to the upper electrode 1122a to compensate for the rectification.
- the DC current source can apply a DC current in the opposite direction to the rectified current to compensate for the rectification.
- the material forming the plurality of electrodes 1122 can be selected to limit or minimize the difference in the thermionic emissions of the plurality of electrodes 1122.
- the colder electrode such as the lower electrode 1122b, can be formed of a material having a higher resistivity than the hotter electrode, such as the upper electrode 1122a, to limit the temperature gradient between the plurality of electrodes 1122.
- the colder electrode 1122b can be formed of an alloy.
- the material forming the plurality of electrodes 1122 can be selected to not interact with the heating process. That is, the material that is non-reactive to alternating current can be selected to form the plurality of electrodes 1122.
- the material that is non-reactive to alternating current can be selected to form the plurality of electrodes 1122.
- aluminum can oxidize at low AC frequencies and result in rectification and is unlikely to be selected.
- the difference in the thermionic emission of the plurality of electrodes 1122 can be limited or reduced by heating the colder electrode 1122b.
- the colder electrode 1122b can be heated resistively by running a current through the electrode 1122b.
- a DC current source can be coupled to the colder electrode 1122b to heat the colder electrode 1122b and reduce the temperature gradient between the plurality of electrodes 1122.
- the magnitude of the current to be compensated for can be determined by first measuring the average DC current that results from the diode effect.
- heating chamber 1210 can include a vertically elongated body 1214 and a plurality of electrodes 1222a, 1222b (herein collectively referred to as the plurality of electrodes 1222).
- An electrical generator 1220 similar to electrical generators 120, 320, 520, 620, 720, 920, 1020, 1120 can excite the plurality of electrodes 1222 to cause conduction and heat the feedstock volumetrically.
- the body 1214 can be formed of a dielectric, non- conductive material.
- the body 1214 can be tubular and the diameter of the body 1214 can be substantially uniform or constant along the length of the body 1214, similar to that of 314, 1014, and 1114.
- the outer surface of the body 1214 can be thermally insulated with RF transparent material on the body 1214.
- a temperature gradient can form across the cross- section of the body 1214.
- the outer wall of the body 1214 can be cooler as there is no I 2 R heating beyond the body 1214.
- a temperature gradient can also occur due to current crowding.
- Current crowding refers to the phenomenon in which current 1224 is higher in the center portion than the portion 1224p around the perimeter of the body 1214, that is the outer sides of the body 1214.
- the current 1224 can crowd slightly in the center of the body 1214. That is, the current density can be greater in the center portion than the outer sides 1224p of the body 1214.
- the magnetic field generated by conduction can cause a Lorentz force.
- the Lorentz force can be weak.
- the Lorentz force can be countered by electrostatic forces as current crowding 1224 can lead to radial potential variation.
- current crowding 1224 can be negligible with currents having a small magnitude.
- current crowding 1224 can be negligible with currents less than 1 Amperes (A).
- A Amperes
- the current density being greater in the center than the outer sides 1224p of the body 1214 can lead to increased local heating in the center. Increased local heating in the center can increase the electrical conductivity, which in turn, further increases current crowding 1224.
- the positive feedback loop of current crowding can be limited by the diffusion and convection currents of the ions. Current crowding can lead to the center portion of the body 1214 being hotter than the outer sides 1224p of the body 1214, which is undesirable.
- the plurality of electrodes 1222 can be excited with a higher frequency.
- the magnetic field can change with time, resulting in the generation of electric fields and eddy currents.
- Eddy currents can reinforce the current 1224 to the outer sides 1224p of the body 1214 and reduce the current 1224 in the center portion of the body 1214.
- the effect of a higher frequency can also be understood as a skin effect. That is, the feedstock can act as an electrical conductor and a higher frequency can cause current 1224 to flow toward the outer sides 1224p of the electrical conductor. Increasing the current density 1224 at the outer sides 1224p of the body 1214 can help warm the outer sides 1224p of the body 1214.
- the body 1214 can be shaped to have a geometry that avoids or limits current crowding. For example, a larger diameter can allow for current crowding. As such, the diameter of the body 1214 can be smaller to avoid current crowding. Furthermore, other shapes to avoid current crowding is possible.
- the temperature and/or heating profile of the heating chamber 1210 can be controlled by, both the shape of the body 1214 and selecting an appropriate frequency. In some embodiments, a uniform temperature can be desirable. In some embodiments, a patterned temperature can be desirable. [167] Returning now to FIG.
- heating chamber 1310 can include a vertically elongated body 1314 and a plurality of electrodes 1322.
- An electrical generator 1320 similar to electrical generators 120, 320, 520, 620, 720, 920, 1020, 1120, 1220 can excite the plurality of electrodes 1322 to cause conduction and heat the feedstock volumetrically.
- the heating chamber 1310 can include an upper portion 1314a and a lower portion 1314b.
- An intermediate electrode 1322b can be coupled between the upper portion 1314a and the lower portion 1314b.
- the intermediate electrode 1322b can be positioned along the vertically elongated body 1314 and between the upper electrode 1322a and lower electrode 1322c at opposite ends of the body 1314. Similar to the upper and lower electrodes 1322a, 1322c, the intermediate electrode 1322b can also form a passage through which the feedstock 1302 or the fluid 1304 passes. [170] In some embodiments, the upper and lower electrodes 1322a, 1322c can be grounded and the intermediate electrode 1322b can be coupled to the electrical generator 1320. This configuration forms two closed loops for the electrical current 1324a, 1324b. Thus, this configuration can help constrain the electrical current 1324a, 1324b within the heating chamber 1310.
- the intermediate electrode 1322b can also help control the heating profile along the length of the elongated body 1314.
- the heating chamber 1310 can include fewer or more heating chamber portions 1314.
- the heating chamber 1310 can include fewer or more electrodes 1322.
- the heating chamber 1310 can be coupled to more electrical generators 1320.
- FIG.14 shown therein is an illustration 1400 of another example heating chamber 1410 for the heating system 100 of FIG.1, in accordance with an example embodiment.
- heating chamber 1410 can include a vertically elongated body 1414 and a plurality of electrodes 1422.
- a plurality of electrical generators 1420a, 1420b, 1420c similar to electrical generators 120, 320, 520, 620, 720, 920, 1020, 1120, 1220, 1320 can excite the plurality of electrodes 1422 to cause conduction and heat the feedstock volumetrically.
- the heating chamber 1410 can include an upper portion 1414a, a lower portion 1414f, and a plurality of intermediate portions 1414b, 1414c, 1414d, 1414e. Similar to heating chamber 1310, a plurality of intermediate electrodes 1422b, 1422c, 1422d, 1422e, 1422f, 1422g can be coupled between the upper portion 1414a and the lower portion 1414f. That is, the intermediate electrodes 1422b, 1422c, 1422d, 1422e, 1422f, 1422g can be positioned along the vertically elongated body 1414 and between the upper electrode 1422a and lower electrode 1422c at opposite ends of the body 1414.
- the intermediate electrodes 1422b, 1422c, 1422d, 1422e, 1422f, 1422g can also form a passage through which the feedstock 1402 or the fluid 1404 passes.
- the upper and lower electrodes 1422a, 1422g and intermediate electrodes 1422c, 1422e can be grounded while intermediate electrodes 1422b, 1422d, and 1422f can be coupled to the electrical generators 1420. Similar to heating chamber 1310, this configuration can help constrain the electrical current within the heating chamber 1410. Furthermore, with additional intermediate electrodes, the heating profile along the length of the elongated body 1414 can be more finely controlled and adjusted.
- the electrodes 1422 can be excited with different frequencies to adjust the shape of heat distribution in the heating chamber 1410. Furthermore, the frequency of the alternating current applied to the electrodes 1422 can vary with time. For example, different frequencies can used depending on the electrical resistance of the feedstock 1402, which can vary with temperature. [175] Although six heating chamber portions 1414a, 1414b, 1414c, 1414d, 1414e, 1414f are shown in FIG.14, the heating chamber 1410 can include fewer or more heating chamber portions 1414. Likewise, although seven electrodes 1422a, 1422b, 1422c, 1422d, 1422e, 1422f, 1422g are shown in FIG.14, the heating chamber 1410 can include fewer or more electrodes 1422.
- the heating chamber 1410 can be coupled to fewer or more electrical generators 1420.
- an electrical generator 1420 can provide a plurality of outputs.
- the plurality of outputs can be obtained from different transformers of the electrical generator 1420 or different taps from a multi-tap transformer connected to the electrical generator 1420.
- heating chamber 1510 can include a vertically elongated body 1514 and a plurality of electrodes 1522a, 1522b (herein collectively referred to as the plurality of electrodes 1522).
- vertically elongated body 1514 can be formed of a dielectric, non-conductive material. Further, the outer surface of the body 1514 can be thermally insulated.
- expansion valve 1516 and separator 1518 are integrated with the vertically elongated body 1510.
- An electrical generator 1520 similar to electrical generators 120, 320, 520, 620, 720, 920, 1020, 1120, 1220, 1320, 1420 can excite the plurality of electrodes 1522 to cause conduction and heat the feedstock volumetrically.
- the heated liquid 1508 can be returned to pump 1512 to be recirculated.
- the separator 1518 can be configured to break the closed electrical circuit formed by the liquid flow path outside of the heating chamber 1510.
- the separator 1518 can be formed of non-conductive materials.
- separator 1518 can be grounded to constrain the electrical current within the heating chamber 1510.
- separator 1518 includes an upper outlet 1518U and a lower outlet 1518L.
- the upper outlet 1518U can be configured to receive vapor 1506 that rises from the fluid.
- the lower outlet 1518L can be configured to receive liquid from the fluid.
- heated liquid 1508 from the fluid can flow into the lower outlet 1518L and to a return orifice 1532.
- the return orifice 1532 can force the heated liquid 1508 into an air chamber 1536 in the form of droplets 1534.
- return orifice 1532 can generate droplets 1534 from the heated liquid 1508, which can break the electrical circuit in the liquid flow path before the heated liquid 1508 returns to pump 1512.
- the separator 1518 generates droplets 1534 in a separately from the separation of vapor 1506 and liquid 1508.
- the separator 1518 can generate droplets 1534 in the same chamber as that in which vapor 1506 and liquid 1508 are separated. [181] Referring now to FIG.16, shown therein is an illustration 1600 of example components of heating system 100 of FIG. 1, in accordance with another example embodiment.
- a heating stage 1630 can include a feedstock supply tank having feedstock 1602 that is pumped by pump 1612 into a vertically elongated body 1614 of a heating chamber 1610.
- the feedstock 1602 can be heated to a fluid by electrical generator 1620 exciting electrodes 1622a, 1622b coupled to the body 1614.
- the fluid can flow to an expansion valve 1616 and a separator 1618.
- the expansion valve 1616 can cause vapor 1606 to flash off the heated liquid 1608.
- the separator 1618 can divert the vapor 1606 away from the heated liquid 1608.
- heat can be recovered from the heated liquid 1608 and/or the vapor 1606 to reduce overall energy use of the system 100. As shown in FIG.
- the heated liquid 1608 can flow from the separator 1618 to a heat exchanger 1640 before it returns to the feedstock 1602 supply tank.
- the heat recovered from the heated liquid 1608 can be used to preheat the feedstock 1602 before it is heated in the heating chamber 1610 within the same heating stage.
- the heat recovered from the heated liquid 1608 can be used to preheat the feedstock 1602 of another heating stage 1630.
- each heating stage 1630 can have a frequency, voltage, temperature, and/or flow rate that is optimized for that stage.
- the vapor 1606 can flow from the separator 1618 to a heat exchanger 1642.
- a heating stage 1730 can include a feedstock supply tank having feedstock 1702 that is pumped by pump 1712 into a vertically elongated body 1714 of a heating chamber 1710. In the heating chamber, the feedstock 1702 can be heated to a fluid by electrical generator 1720.
- the fluid can flow to an expansion valve 1716 and a separator 1718.
- the expansion valve 1716 can cause vapor 1706 to flash off the heated liquid 1708.
- the separator 1718 diverts the vapor 1706 away from the heated liquid 1708.
- separator 1718 can form droplets 1734 from the heated liquid 1708.
- separator 1718 can force the heated liquid 1708 through a spray tube 1732 to generate droplets 1734 to reduce any electrical current in the feedstock 1702 outside of the heating chamber 1710.
- the heated liquid 1708 can flow to another heating stage, similar to heating stage 1730.
- FIG.18 shown therein is an illustration 1800 of example components of heating system 100 of FIG. 1, in accordance with another example embodiment.
- a heating stage 1830 can include a feedstock supply tank having feedstock 1802 that is pumped by pump 1812 into a vertically elongated body 1814 of a heating chamber 1810.
- the feedstock 1802 can be heated to a fluid by electrical generator 1820 exciting electrodes 1822a, 1822b coupled to the body 1814.
- the fluid can flow to an expansion valve 1816 and a separator 1818.
- the expansion valve 1816 can cause vapor 1806 to flash off the heated liquid 1808.
- the separator 1818 can divert the vapor 1806 away from the heated liquid 1808. Similar to separators 1518, 1718, the separator 1818 can include a spray tube 1832 to form droplets 1834 from the heated liquid 1808.
- a vacuum system 150 including a vacuum pump 1852 and a level control valve 1854, can be used to adjust the pressure of the feedstock 1802 and thereby the overall system pressure to an initial pressure (P i ).
- the vacuum pump 1852 can draw gas 1856 out of the feedstock supply.
- the vacuum pump 1852 and level control valve 1854 can reduce the ambient pressure of the feedstock 1802 to the initial pressure (Pi) so that the boiling point can be at a lower temperature than the ambient pressure.
- the vacuum system 150 can reduce the overall system pressure to be less than 100 kPa.
- Some types of feedstock 1802 can be temperature-sensitive and degrade at a particular temperature.
- the heating system 100 can include a control system (not shown in FIG. 1). The control system can operate to control and/or monitor the operation of the heating system 100. In some embodiments, the heating system 100 can include fewer or more control systems.
- control system can be dedicated to one or more heating stages.
- the control system can include control interfaces that allow a user to configure the heating system 100.
- the control system can select control parameters for the heating system, such as the control parameters for the vacuum system 1850, the pump 112 and/or the electrical generator 120, including but not limited to the initial pressure (P i ), the flow rate, the maximum temperature of the body 114, the waveform, the magnitude, and/or the frequency of the output of the electrical generator 120.
- the control parameters can be determined by the control system.
- control parameters can be determined based on the physical properties of the body 114, including the length of the body 114, the cross-sectional area of the body, a desire heating profile along the length of the body 114, or the conductivity of the feedstock 102, which can vary depending on the progress of the heating process.
- the control system can include a processor, a storage component, and/or a communication component.
- the processor can control the operation of the control system.
- the processor can include any suitable processors, controllers, digital signal processors, graphics processing units, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), microcontrollers, and/or other suitably programmed or programmable logic circuits that can provide sufficient processing power depending on the configuration, purposes and requirements of the control system.
- the processor can include more than one processor with each processor being configured to perform different dedicated tasks.
- the storage component can include RAM, ROM, one or more hard drives, one or more flash drives or some other suitable data storage elements such as disk drives.
- the storage component can include volatile and non-volatile memory.
- Non-volatile memory can store computer programs consisting of computer- executable instructions, which can be loaded into the volatile memory for execution by the processor. Operating the processor to carry out a function can involve executing instructions (e.g., a software program) that can be stored in the storage component and/or transmitting or receiving inputs and outputs via the communication component.
- the storage component can also store data input to, or output from, the processor, which can result from the course of executing the computer-executable instructions for example.
- the storage component can include one or more databases for storing data related to the heating system 100.
- the storage component can store data in respect of the operation of the heating system 100, such as data in respect of the heating stages, the vacuum system 1850, the pump 112, and/or the electrical generator 120.
- the communication component can include any interface that enables the control system to communicate with various devices and other systems.
- the communication component can facilitate communication with the other components of the heating system 100, such as the electrical generator 120, a system storage component, or instrumentation and control devices via the communication network.
- one or more computing devices can communicate with the heating system 100 via the communication network.
- a user may electronically configure the heating system 100 using the computing device.
- the computing device can include any device capable of communication with other devices through a network such as the communication network.
- the computing device can include a processor and memory, and may be an electronic tablet device, a personal computer, workstation, server, portable computer, mobile device, personal digital assistant, laptop, smart phone, Wireless Application Protocol (WAP) phone, and portable electronic devices or any combination of these.
- FIG.19 is a flowchart of an example method 1900 for heating a feedstock in at least one heating stage. To assist with the description of method 1900, reference will be made simultaneously to FIGS.1 to 18.
- the heating chamber can be any heating chamber, such as heating chambers 310, 510, 610, 710, 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710, or 1810.
- the electrodes can be any electrodes, such as electrodes 616, 622b, 716, 822, 922, 1022, 1122, 1222, 1322, 1422, or 1522. Furthermore, the following description refers to one heating stage but can apply to each heating stage. Any one or more of steps 1910 to 1950 for a heating stage can be performed simultaneously or successively with the performance of one or more steps of 1910 to 1950 for another heating stage.
- a feedstock such as feedstock 102
- a pump such as pump 112 can pump the feedstock 102 into the vertically elongated body 114.
- the feedstock 102 can include an electrically conductive liquid having an initial temperature (T i ) and an initial pressure (P i ).
- at least one vacuum system such as vacuum system 1850 can be configured to control the initial temperature (Ti) and an initial pressure (Pi) of the feedstock 102.
- at least one alternating current can be applied to the feedstock 102 within the vertically elongated body 114 to heat the feedstock volumetrically to a saturation temperature (Ts) while the feedstock remains at the initial pressure (Pi).
- an electrical generator such as electrical generator 120 can apply the alternating current to the feedstock via a plurality of electrodes 322 coupled to the vertically elongated body 114.
- the feedstock 102 can be a fluid at the saturation temperature (T s ).
- T s saturation temperature
- the fluid can exit from an upper portion of the vertically elongated body 314 as the pump 112 continues to pump 112 feedstock 102 into the vertically elongated body 314.
- the pressure of the fluid can be reduced from the initial pressure (Pi) to a lower pressure (Pl).
- an expansion valve such as expansion valve 116 can reduce the pressure of the fluid from the initial pressure (P i ) to the lower pressure (P l ).
- An example of this reduction in pressure is shown as line 210 of FIG.2A or line 224 of FIG.2B.
- the reduction in pressure can cause vapor 106 to flash off from the fluid and thereby dehydrate the feedstock 102.
- the vapor 106 can be separated from heated liquid 108 of the fluid.
- the heated liquid 108 can have a residual temperature that is higher than the initial temperature (Ti) and lower than the saturation temperature (Ts).
- the heated liquid 108 can be recirculated through the same heating stage 130.
- the heated liquid 108 can progress to another heating stage 130 to be furthered heated and/or dehydrated.
- heat can be recovered from the vapor 106 and/or the heated liquid 108 to preheat the feedstock 102 of the same heat stage 130 or the feedstock 102 of another heating stage 130.
- the programmable computers may be a server, network appliance, embedded device, computer expansion module, a personal computer, laptop, personal data assistant, cellular telephone, smart-phone device, tablet computer, a wireless device or any other computing device capable of being configured to carry out the methods described herein.
- the communication interface may be a network communication interface.
- the communication interface may be a software communication interface, such as those for inter-process communication (IPC).
Landscapes
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Microbiology (AREA)
- Health & Medical Sciences (AREA)
- Biomedical Technology (AREA)
- Biotechnology (AREA)
- Molecular Biology (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Physical Or Chemical Processes And Apparatus (AREA)
Abstract
Systems and methods for heating a feedstock are disclosed. The system includes at least one heating stage. Each heating stage includes at least one pump, a heating chamber including a vertically elongated body and a plurality of electrodes coupled to the body, an expansion valve downstream of the body, a separator downstream of the expansion valve, and at least one electrical generator operable to excite the plurality of electrodes. The feedstock can include a conductive liquid that is pumped into the body. In the body, the electrodes can apply at least one alternating current to the feedstock to heat the feedstock volumetrically to a fluid at a saturation temperature while the feedstock remains at the initial pressure. The expansion valve can reduce a pressure of the fluid, which can cause vapor to flash off from the fluid. The separator can separate the vapor from heated liquid of the fluid.
Description
Title: Systems and Methods for Heating a Conductive Feedstock Field [1] The described embodiments relate generally to systems and methods for heating, and in particular, systems and methods of heating a conductive feedstock. Background [2] In many industrial settings, processed materials may need to be heated. For example, industrial drying involves removing water of a material, such as dehydration or lowering moisture content. Another application can be heating of water in industrial processes, or in commercial buildings. [3] Heating is typically achieved by burning fossil fuels or by applying electrical heating elements to deliver heat by surface transfer to the material. Heating can also be accomplished by electromagnetic radiation, such as in a microwave oven. However, such heating methods can be inefficient, difficult to scale to industrial size, slow, and yield non- uniform heating of the material. Summary [4] This summary is intended to introduce the reader to the more detailed description that follows and not to limit or define any claimed or as yet unclaimed invention. One or more inventions may reside in any combination or sub-combination of the elements or process steps disclosed in any part of this document including its claims and figures. [5] The various embodiments described herein generally relate to systems for heating a feedstock and related methods. [6] In accordance with an aspect of this disclosure, there is provided a system for heating a feedstock. The system includes at least one heating stage, each heating stage can include at least one pump for pumping the feedstock, a heating chamber comprising a vertically elongated body and a plurality of electrodes coupled to the vertically elongated body, an expansion valve downstream of the vertically elongated body, a separator downstream of the expansion valve, and at least one electrical
generator operable to excite the plurality of electrodes. The feedstock can include a conductive liquid having an initial temperature and an initial pressure. The vertically elongated body can include an upper portion and a lower portion. The lower portion can be configured to receive the pumped feedstock. The plurality of electrodes can be operable to apply at least one alternating current to the feedstock within the vertically elongated body to heat the feedstock volumetrically to a saturation temperature while the feedstock remains at the initial pressure. The feedstock can be a fluid at the saturation temperature. The expansion valve can be operable to reduce a pressure of the fluid from the initial pressure to a lower pressure. The reduction in pressure can cause vapor to flash off from the fluid. The separator can be configured to separate the vapor from heated liquid of the fluid. The heated liquid can have a residual temperature that is higher than the initial temperature and lower than the saturation temperature. [7] In some embodiments, for one or more heating stages of the at least one heating stage, the plurality of electrodes can include at least an upper electrode and a lower electrode positioned at opposite ends of the vertically elongated body. The lower electrode can include a passage through which the feedstock passes. The upper electrode can include a passage through which the fluid passes. [8] In some embodiments, the system can further include, for the one or more heating stages of the at least one heating stage, at least one intermediate electrode positioned along the vertically elongated body and between the opposite ends. The at least one intermediate electrode can include a passage through which at least a portion of the feedstock or the fluid passes. [9] In some embodiments, the at least one electrical generator can be coupled to one or more intermediate electrodes of the at least one intermediate electrode to control a heating profile of the feedstock within the heating chamber. [10] In some embodiments, each of the upper electrode and the lower electrode can be grounded. [11] In some embodiments, the passage within each electrode of the plurality of electrodes can include a plurality of protrusions to increase a surface area of the electrode that is in contact with the feedstock.
[12] In some embodiments, the system can further include a DC current source coupled to the upper electrode to compensate for rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode. [13] In some embodiments, the system can further include a capacitor electrically connected in series between the upper electrode and the at least one electrical generator to avoid rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode. [14] In some embodiments, the lower electrode can be formed of a material having a higher resistivity than the upper electrode to minimize a temperature gradient between the upper electrode and the lower electrode. [15] In some embodiments, the system can further include a DC current source coupled to the lower electrode to heat the lower electrode resistively to minimize a temperature gradient between the upper electrode and the lower electrode. [16] In some embodiments, for the one or more heating stages of the at least one heating stage, the vertically elongated body can include a length and a cross- sectional area adapted to enable a desired heating profile along the length of the vertically elongated body. [17] In some embodiments, for the one or more heating stages of the at least one heating stage, the vertically elongated body can include a tube having a uniform diameter along a length of the tube. [18] In some embodiments, for the one or more heating stages of the at least one heating stage, the vertically elongated body can include a tube having a varying diameter along a length of the tube. [19] In some embodiments, for the one or more heating stages of the at least one heating stage, the upper portion can have a diameter that is smaller than a diameter of the lower portion to increase a velocity of the fluid. [20] In some embodiments, for the one or more heating stages of the at least one heating stage, the expansion valve can include an inlet formed by the upper electrode.
[21] In some embodiments, the expansion valve can further include an outlet adjoined to the separator. [22] In some embodiments, for the one or more heating stages of the at least one heating stage, the separator can include a return orifice configured to allow the heated liquid to return to the at least one pump, thereby reducing electrical current outside of the vertically elongated body. [23] In some embodiments, for the one or more heating stages of the at least one heating stage, the lower portion can have a diameter that is smaller than a diameter of the upper portion to accelerate the heating of the feedstock. [24] In some embodiments, for the one or more heating stages of the at least one heating stage: the vertically elongated body can be formed of an elastic material; and the system can further include a toroidal actuator coupled to a portion of the vertically elongated body. The toroidal actuator can be operable to adjust a diameter of the portion of the vertically elongated body. [25] In some embodiments, for the one or more heating stages of the at least one heating stage, the heating chamber can further include insulation around at least the vertically elongated body to reduce heat loss. The insulation can be formed of an RF- transparent material. [26] In some embodiments, for one or more heating stages of the at least one heating stage, the plurality of electrodes can include coaxial electrodes. [27] In some embodiments, for one or more heating stages of the at least one heating stage, the plurality of electrodes can include parallel plate electrodes. [28] In some embodiments, for one or more heating stages of the at least one heating stage, the plurality of electrodes can be formed of a material that is non-reactive to the alternating current. [29] In some embodiments, for one or more heating stages of the at least one heating stage, the at least one electrical generator can be operable to adjust one or more of a frequency or a voltage of each alternating current of the at least one alternating current. [30] In some embodiments, the system can further include a processor operable to adjust the at least one electrical generator based on one or more of a desired heating
profile along a length of the vertically elongated body, a cross-sectional area of the vertically elongated body, or a conductivity of the feedstock. [31] In some embodiments, for one or more heating stages of the at least one heating stage, each electrical generator of the at least one electrical generator can include at least one transformer for generating the at least one alternating current. [32] In some embodiments, for one or more heating stages of the at least one heating stage, the frequency of the alternating current can be greater than 100 Hz. [33] In some embodiments, for one or more heating stages of the at least one heating stage, the at least one electrical generator can include one or more of a radio frequency (RF) generator, an alternating current (AC) generator, a microwave generator, or a millimeter wave generator. [34] In some embodiments, the system can further include, at least one heat exchanger for one or more heating stages of the at least one heating stage, the at least one heat exchanger can be downstream of the separator and configured to recover energy for pre-heating the feedstock. [35] In some embodiments, the at least one heat exchanger downstream of the separator can be configured to recover energy from the vapor; and the system can further include a condensate tank downstream of the heat exchanger for collecting condensate from cooling the vapor. [36] In some embodiments, the at least one heat exchanger downstream of the separator can be configured to recover energy from the heated liquid. [37] In some embodiments, the at least one heating stage can include a plurality of heating stages; and the energy recovered from one heating stage of the plurality of heating stages can be used to pre-heat feedstock of another heating stage of the plurality of heating stages. [38] In some embodiments, the system can include at least one vacuum system to control the temperature of the feedstock at each heating stage of the at least one heating stage. [39] In some embodiments, the feedstock can include brine. [40] In some embodiments, the feedstock can include non-soluble particles. [41] In some embodiments, the vapor can include steam.
[42] In accordance with another aspect of this disclosure, there is a method for heating a feedstock in at least one heating stage. The method can involve, for each heating stage of the at least one heating stage: pumping the feedstock into a lower portion of a vertically elongated body, the feedstock including a conductive liquid having an initial temperature and an initial pressure; and applying at least one alternating current to the feedstock within the vertically elongated body to heat the feedstock volumetrically to a saturation temperature while the feedstock remains at the initial pressure. The feedstock can be a fluid at the saturation temperature. The method can further involve allowing the fluid to exit from an upper portion of the vertically elongated body; after the fluid has exited the vertically elongated body, reducing a pressure of the fluid from the initial pressure to a lower pressure, the reduction in pressure causing vapor to flash off from the fluid; and separating the vapor from heated liquid of the fluid. The heated liquid can have a residual temperature that is higher than the initial temperature and lower than the saturation temperature. [43] In some embodiments, the method can involve, for one or more heating stages of the at least one heating stage: pumping the feedstock through a lower electrode positioned at a lower end of the vertically elongated body; positioning an upper electrode at an upper end of the vertically elongated body to allow fluid to pass therethrough; and exciting the lower electrode and the upper electrode to apply the at least one alternating current to the feedstock. [44] In some embodiments, the method can involve, for the one or more heating stages of the at least one heating stage, positioning at least one intermediate electrode along the vertically elongated body and between the upper electrode and the lower electrode to allow at least a portion of the feedstock or the fluid to pass therethrough. [45] In some embodiments, the method can involve, for the one or more heating stages of the at least one heating stage, applying the at least one alternating current to the at least one intermediate electrode to control a heating profile of the feedstock within the vertically elongated body. [46] In some embodiments, the method can involve, grounding each of the upper electrode and the lower electrode.
[47] In some embodiments, the method can involve, providing a plurality of protrusions within each electrode to increase a surface area of the electrode that is in contact with the feedstock. [48] In some embodiments, the method can involve, applying a DC current to the upper electrode to compensate for rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode. [49] In some embodiments, the method can involve, discharging a capacitor to avoid rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode. [50] In some embodiments, the method can involve, forming the lower electrode of a material having a higher resistivity than the upper electrode to minimize a temperature gradient between the upper electrode and the lower electrode. [51] In some embodiments, the method can involve, resistively heating the lower electrode to minimize a temperature gradient between the upper electrode and the lower electrode. [52] In some embodiments, the method can involve, for the one or more heating stages of the at least one heating stage, the vertically elongated body can include a length and a cross-sectional area adapted to enable a desired heating profile along the length of the vertically elongated body. [53] In some embodiments, the method can involve, for the one or more heating stages of the at least one heating stage, the vertically elongated body can include a tube having a uniform diameter along a length of the tube. [54] In some embodiments, the method can involve, for the one or more heating stages of the at least one heating stage, the vertically elongated body can include a tube having a varying diameter along a length of the tube. [55] In some embodiments, the method can involve, for the one or more heating stages of the at least one heating stage, increasing a velocity of the fluid by configuring the upper portion to have a diameter that is smaller than a diameter of the lower portion. [56] In some embodiments, the method can involve, for the one or more heating stages of the at least one heating stage, the expansion valve can include an inlet formed by the upper electrode.
[57] In some embodiments, the expansion valve can further include an outlet adjoined to the separator. [58] In some embodiments, the method can involve reducing electrical current outside of the vertically elongated body by returning the heated liquid to the feedstock to be pumped into the vertically elongated body. [59] In some embodiments, the method can involve for the one or more heating stages of the at least one heating stage, accelerating the heating of the feedstock by configuring the lower portion to have a diameter that is smaller than a diameter of the upper portion. [60] In some embodiments, the method can involve, for the one or more heating stages of the at least one heating stage: the vertically elongated body can be formed of an elastic material; and the method can involve operating a toroidal actuator coupled to a portion of the vertically elongated body to adjust a diameter of the portion of the vertically elongated body. [61] In some embodiments, the method can involve reducing heat loss by providing insulation around at least the vertically elongated body. The insulation can be formed of an RF-transparent material. [62] In some embodiments, the method can involve, for one or more heating stages of the at least one heating stage, exciting coaxial electrodes coupled to the vertically elongated body to apply the at least one alternating current to the feedstock. [63] In some embodiments, the method can involve, for one or more heating stages of the at least one heating stage, exciting parallel plate electrodes coupled to the vertically elongated body to apply the at least one alternating current to the feedstock. [64] In some embodiments, each electrode can be formed of a material that is non-reactive to the alternating current. [65] In some embodiments, the method can involve, for one or more heating stages of the at least one heating stage, adjusting one or more of a frequency or a voltage of each alternating current of the at least one alternating current. [66] In some embodiments, adjusting one or more of a frequency or a voltage of each alternating current of the at least one alternating current can be based on one or
more of a desired heating profile along a length of the vertically elongated body, a cross- sectional area of the vertically elongated body, or a conductivity of the feedstock. [67] In some embodiments, the frequency of the alternating current can be greater than 100 Hz. [68] In some embodiments, the method can involve using one or more of a radio frequency (RF) generator, an alternating current (AC) generator, a microwave generator, or a millimeter wave generator to apply the at least one alternating current to the feedstock. [69] In some embodiments, the method can involve, for one or more heating stages of the at least one heating stage, recovering energy from the fluid to pre-heat the feedstock. [70] In some embodiments, recovering energy from the fluid can involve recovering energy from the vapor; and the method can involve collecting condensate from cooling the vapor. [71] In some embodiments, recovering energy from the fluid can involve recovering energy from the heated liquid. [72] In some embodiments, the at least one heating stage can include a plurality of heating stages; and the method can involve using energy recovered from one heating stage of the plurality of heating stages to pre-heat feedstock of another heating stage of the plurality of heating stages. [73] In some embodiments, the method involves operating at least one vacuum system to control the temperature of the feedstock at each heating stage of the at least one heating stage. [74] In some embodiments, the feedstock can include brine. [75] In some embodiments, the feedstock can include non-soluble particles. [76] In some embodiments, the vapor can include steam. Brief Description of the Drawings [77] Several embodiments will now be described in detail with reference to the drawings, in which:
FIG. 1 is a block diagram of example components of an example system for heating a conductive feedstock, in accordance with an example embodiment; FIG.2A is a diagram of an example pressure change in the system of FIG.1, in accordance with an example embodiment; FIG.2B is a diagram of another example pressure change in the system of FIG.1, in accordance with another example embodiment; FIG.3 is an illustration of an example heating chamber for the system of FIG.1, in accordance with an example embodiment; FIG. 4 is another illustration of the example heating chamber of FIG. 3, in accordance with an example embodiment; FIG.5 is an illustration of another example heating chamber for the system of FIG. 1, in accordance with an example embodiment; FIG.6 is an illustration of another example heating chamber for the system of FIG. 1, in accordance with an example embodiment; FIG. 7 is an illustration of a portion of another example heating chamber for the system of FIG.1, in accordance with an example embodiment; FIG. 8 is an illustration of an example electrode of another example heating chamber for the system of FIG.1, in accordance with an example embodiment; FIG.9 is an illustration of another example heating chamber for the system of FIG. 1, in accordance with an example embodiment; FIG. 10A is an electrical representation of an example heating chamber for the system of FIG.1, in accordance with another example embodiment; FIG.10B is another electrical representation of an example heating chamber for the system of FIG.1, in accordance with another example embodiment; FIG.11 is an electrical representation of another example heating chamber for the system of FIG.1, in accordance with another example embodiment;
FIG. 12 is an illustration of current crowding occurring in an example heating chamber for the system of FIG.1, in accordance with another example embodiment; FIG. 13 is an illustration of an example heating chamber with a plurality of electrodes for the system of FIG.1, in accordance with an example embodiment; FIG. 14 is an illustration of another example heating chamber with a plurality of electrodes for the system of FIG.1, in accordance with an example embodiment; FIG.15 is an illustration of another example of components of the system of FIG. 1, in accordance with another example embodiment; FIG. 16 is a diagram of example components of the system of FIG. 1, in accordance with another example embodiment; FIG. 17 is a diagram of example components of the system of FIG. 1, in accordance with another example embodiment; FIG.18 is a diagram of another example of components of the system of FIG.1, in accordance with another example embodiment; and FIG.19 is a flowchart of an example method for heating a conductive feedstock, in accordance with an example embodiment. [78] The drawings, described below, are provided for purposes of illustration, and not of limitation, of the aspects and features of various examples of embodiments described herein. For simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn to scale. The dimensions of some of the elements may be exaggerated relative to other elements for clarity. It will be appreciated that for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements or steps. Description of Example Embodiments [79] Conventionally, materials can be heated by surface transfer. However, energy loss can occur in the transfer of heat from the heating element to the material. As well, the diffusion of heat from the surface throughout the material can be slow.
Furthermore, temperature variations can occur within the material as the heat diffuses – that is the heating can be non-uniform. [80] In contrast to surface transfer of heat, the systems and method disclosed herein transfer heat to a feedstock volumetrically, which can be faster, deliver higher power, and result in less temperature variation. Furthermore, the application of an alternating current to the feedstock can be controlled, which in turn allows for control of the heating profile of the feedstock. [81] Disclosed herein are systems and methods for heating a feedstock, such as a conductive liquid. For example, the disclosed systems and methods can involve at least one heating stage. Each heating stage can include at least one pump for pumping the feedstock, a heating chamber including a vertically elongated body and a plurality of electrodes coupled to the vertically elongated body, an expansion valve downstream of the vertically elongated body, a separator downstream of the expansion valve, and at least one electrical generator operable to excite the plurality of electrodes. The vertically elongated body includes an upper portion and a lower portion. The lower portion is configured to receive the pumped feedstock. The feedstock includes a conductive liquid having an initial temperature and an initial pressure. The plurality of electrodes are operable to apply at least one alternating current to the feedstock within the vertically elongated body to heat the feedstock volumetrically to a saturation temperature while the feedstock remains at the initial pressure. The feedstock is a fluid at the saturation temperature. The expansion valve is operable to reduce a pressure of the fluid from the initial pressure to a lower pressure. The reduction in pressure causes vapor to flash off from the fluid. The separator is configured to separate the vapor from heated liquid of the fluid, the heated liquid having a residual temperature that is higher than the initial temperature and lower than the saturation temperature. [82] Referring now to FIG. 1, shown therein is a block diagram illustrating example components of an example heating system 100. To assist with the description of heating system 100, reference will be made simultaneously to FIGS.2A and 2B. [83] The heating system 100 can include one or more heating stages 130. Each heating stage 130 can include a pump 112, a heating chamber 110, an expansion valve
116, a separator 118, and an electrical generator 120. Although only one heating stage is shown in FIG.1, the system can include additional heating stages. [84] The feedstock 102 can be any liquid with increased conductivity. For example, the feedstock 102 can be a liquid brine, such as sodium chloride (NaCl), potassium chloride (KCl), or any liquid with electrical conductivity, that is, any liquid having free ions or other electrical loss mechanisms. In some embodiments, the water may not be de-ionized. In some embodiments, the feedstock 102 can include different solutes dissolved together. In some embodiments, the feedstock 102 can include suspended particles that are non-soluble. In some embodiments, electrically conductive liquids other than water may be used. [85] Heating the feedstock 102 can remove or evaporate liquids from the feedstock 102. For example, heating a feedstock 102 containing water can remove at least some of the water content, and thereby dehydrate the feedstock 102. Other liquids can also be removed from the feedstock 102. [86] Dehydration can occur because ions in the conductive feedstock 102, such as sodium and chloride ions, can be larger and have stronger intermolecular forces compared to water molecules. These intermolecular forces can keep the ions in the liquid phase even at elevated temperatures. When the feedstock 102 is boiled, the vapor that forms can be pure water vapor, while the ions remain in the liquid portion of the feedstock 102. [87] The pump 112 can be any appropriate pump that moves the feedstock to the heating chamber 110. For example, pump 112 can be a peristaltic pump. In some embodiments, such as when the feedstock 102 is viscous, the pump 112 can be a cavity progressive pump. The feedstock 102 at the output of the pump 112 can have an initial pressure (Pi). The initial pressure (Pi) of the feedstock 102 can be above, at, or below the ambient pressure of the feedstock 102. In some embodiments, the ambient pressure can be atmospheric pressure, such as approximately 100 kPa or 101.3 kPa kPa. Although only one pump 112 is shown in FIG.1, a heating stage can include additional pumps 112. [88] The heating chamber 110 can include a vertically elongated body 114 having an upper portion 114U and a lower portion 114L. The vertically elongated body 114 can be provided by a body that is elongated along a longitudinal axis and mounted
vertically such that the longitudinal axis is vertical. The body 114 can be formed of a non- conductive material. In some embodiments, the body 114 can be formed of an elastic material. In some embodiments, the body 114 can be formed of ceramic, glass or composite materials. In some embodiments, the body 114 can be formed of a plurality of layers. For example, while an interior layer of the body 114 can be formed of a non- conductive material, at least part of another layer of the body 114 can be formed of a metal for mechanical integrity. In some embodiments, at least part of another layer of the body 114 can be provided for thermal insulation. As shown in FIG.1, pump 112 can pump the feedstock 102 into the lower portion of the vertically elongated body 114L. [89] In the heating chamber 110, the feedstock 102 from the pumps 112 having an initial temperature (Ti) can be volumetrically heated to a saturation temperature (Ts) while it remains at the initial pressure (Pi). In some embodiments, the pressure of the feedstock 102 can become elevated as the feedstock 102 is heated. The feedstock 102 is a fluid at the saturation temperature (Ts). In some embodiments, the feedstock 102 can be an industrial liquid that can be heated to temperatures higher than 100°C. In some embodiments, the feedstock 102 can be a liquid in food processing where the maximum temperature can be significantly less than 100°C. [90] The feedstock fluid can exit the upper portion of the vertically elongated body 114U and pass through the expansion valve 116 downstream of the vertically elongated body 114. The expansion valve 116 is operable to reduce the pressure of the feedstock fluid from the initial pressure (Pi) to a lower pressure (Pl). For example, the expansion valve 116 can be a variable restriction valve. [91] Referring now to FIG. 2A, shown therein is a pressure-enthalpy diagram 200 for water in which pressure is shown on the vertical axis and enthalpy is shown on the horizontal axis. Water is a saturated liquid along curve 204 and changes phase to a saturated, or sub-cooled liquid in region 202, that is, to the left of the saturated liquid curve 204. Water changes phase to a vapor in region 206, that is, water is superheated to the right of the saturated liquid curve 204. As shown in FIG.2A, the proportion of water that is vapor increases further to the right of the saturated liquid curve 204. For example, the proportion of water that is vapor along curve 208a is 10%, 20% along curve 208b, and 30% along curve 208c, etc.…
[92] The expansion valve 116 can reduce the pressure of the fluid along line 210 on FIG. 2A. The reduction in pressure can cause vapor to flash off from the fluid. For example, the reduction in pressure can cause steam to flash off the fluid. In the example of flashing off along line 210, that is, from the saturated liquid curve 204 at the saturation temperature (Ts) of 100°C, 7% of water can be flashed off as steam, in some embodiments. In some embodiments, by flashing off vapor such as steam, the feedstock 102 can be dehydrated. [93] Returning now to FIG.1, the separator 118 is downstream of the expansion valve 116. After passing through the expansion valve 116, the feedstock fluid enters the separator 118. The separator 118 is configured to separate the vapor 106 from heated liquid 108 of the fluid. The heated liquid 108 has a residual temperature (Tr) that is higher than the initial temperature (Ti) of the feedstock 102 and lower than the saturation temperature (Ts). [94] In some embodiments, the heated liquid 108 can be recirculated (not shown in FIG.1) within the heating stage 130. That is, the heated liquid 108 can be added to feedstock 102 and returned to pump 112. [95] In some embodiments, the heated liquid 108 can flow to another heating stage, similar to heating stage 130. Additional heating stages 130 can be used to further dehydrate the feedstock 102. In some embodiments, the number of heating stages 130 required can be reduced by increasing the amount of vapor 106 that is flashed off within a single heating stage 130. [96] For example, the feedstock 102 can be further heated at the saturation temperature (Ts) to increase the vapor. Referring now to FIG.2B, the feedstock 102 can be further heated along line 222 to increase the amount of vapor. That is, the feedstock 102 can be further heated at the saturation temperature to increase the vapor from V1 on the saturated liquid curve 204 to V2 on curve 208a. Flashing off along line 224, that is, from the curve 208a when there is more vapor can result in flashing off 17% of water as steam. [97] The heating chamber 110 includes a plurality of electrodes (not shown in FIG.1) coupled to the vertically elongated body 114. The electrical generator 120 can be coupled to the plurality of electrodes to excite the plurality of electrodes. Excitation of the
plurality of electrodes applies current to the feedstock 102 within the body 114 to heat the feedstock 102 volumetrically. [98] In some embodiments, the electrical generator 120 can be an alternating current (AC) generator, a radio frequency (RF) generator, a microwave generator, or a millimeter wave generator. Although only one electrical generator 120 is shown in FIG.1, a heating stage 130 can include additional electrical generators 120. [99] In some embodiments, various components of the heating system 100 are thermally insulated. For example, insulation can be provided on the outer surface of the vertically elongated body 114 and/or the separator 118 to reduce heat loss. Further, the insulation on the outer surface of the vertically elongated body 114 can be RF- transparent. [100] Referring now to FIG.3, shown therein is an illustration 300 of an example heating chamber 310 for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to heating chamber 110, heating chamber 310 can include a vertically elongated body 314 and a plurality of electrodes 322. [101] The body 314 can be formed of a dielectric, non-conductive material. As shown in FIG.3, the body 314 can be tubular. Furthermore, in the embodiment shown in FIG.3, the diameter of the body 314 can be substantially uniform or constant along the length of the body 314. In other embodiments, the diameter of the body 314 can vary along the length of the body 314. In some embodiments, the outer surface of the body 314 can be thermally insulated. [102] The heating chamber 310 shown in FIG.3 is shown for illustrative purposes. Other configurations are possible. For example, the dimensions of the body 314 can vary. In some embodiments, the length of the body 314 can be significantly greater than the diameter of the body 314. For example, the body 314 can have a length in the order of approximately 20 times the inner diameter of the body 314. As a further example, the body 314 can have an inner diameter of approximately 1 inch and the length of the body 314 can be approximately 23 inches. Other sizes are possible. [103] Each electrode of the plurality of electrodes 322 can be formed of an electrically conductive metal or ceramic. The plurality of electrodes 322 can include an upper electrode 322a and a lower electrode 322b. As shown in FIG.3, the upper electrode
322a and the lower electrode 322b can be positioned at opposite ends of the vertically elongated body 314. Each of the upper electrode 322a and the lower electrode 322b are electrically connected to an electrical generator 320, which can be similar to electrical generator 120. Excitation of the plurality of electrodes 322 applies a current 324 to the electrically conductive feedstock 302 within the body 314. The current 324 causes electrical conduction, which heats the feedstock 302 volumetrically. [104] The lower electrode 322b can define a passage therein. For example, the lower electrode 322b can be a ring or sleeve. Feedstock 302 can flow through the passage of the lower electrode 322b and enter the body 314. Within the body 314, the feedstock 302 is heated to the saturation temperature (Ts). At the saturation temperature (Ts), the feedstock is a fluid. The upper electrode 322a can define a passage therein as well. Similarly, the upper electrode 322a can be a ring or sleeve. The feedstock fluid, that is, heated feedstock 302 flows through the passage of the upper electrode 322a and exits the body 314. [105] The plurality of electrodes 322 shown in FIG. 3 is shown for illustrative purposes. Other electrode configurations are possible. For example, the plurality of electrodes can have a coaxial arrangement. That is, the plurality of electrodes can include an inner electrode and an outer electrode coaxial with the inner electrode, and the body of the heating chamber can be positioned within an annulus formed between the inner electrode and the outer electrode. In another example, the plurality of electrodes can have a parallel plate arrangement. That is, the plurality of electrodes can include at least a pair of parallel plates and the body of the heating chamber can be sandwiched between the parallel plates. In yet another example, the plurality of electrodes can have a helical arrangement. [106] In some embodiments, the electrical generator 320 can generate an alternating high voltage. The waveform and/or the frequency of the output of the electrical generator 320 can be any appropriate waveform and/or frequency. For example, the output of the electrical generator 320 can be a sinusoidal waveform with a peak voltage of about 1000 V and a frequency of about 25 kHz. In other embodiments, the output of the electrical generator 320 may not be sinusoidal. In other embodiments, the output of
the electrical generator 320 can have a higher frequency, a lower frequency, or include a plurality of frequency components (i.e., broad spectrum signal). [107] In some embodiments, the output of the electrical generator 320 can be a radio frequency (RF) signal. Use of an RF signal can be advantageous over the use of a low frequency AC or a DC signal because an RF signal can be easier to control and more cost effective. For example, RF transformers can have a smaller form factor and RF switching transistor can be highly efficient. Thus, the electrical generator 320 can be simpler and less expensive to manufacture. In some embodiments, the frequency of the output of the electrical generator 320 can be in the range of 10 kHz to 500 kHz. In some embodiments, the frequency of the output of the electrical generator 320 can be greater than 100 Hz. [108] Current from electrical conduction can dissipate heat to the feedstock 302 via I2R dissipation. The electrical conduction can vary depending on the electrical conductivity of the feedstock 302. To provide sufficient current to generate I2R dissipation, the magnitude of the alternating high voltage applied can depend on the electrical conductivity of the feedstock 302. For example, a higher voltage can be applied when the electrical conductivity of the feedstock 302 is lower. Conversely, a lower voltage can be applied when the electrical conductivity of the feedstock 302 is higher. The transfer of heat energy results from the I2R dissipation in which I is the current of the electrical generator 320 and R is the equivalent electrical resistance between the upper electrode 322a and the lower electrode 322b. [109] As an example, the body 314 can be a cylinder having an inner diameter of approximately 1 inch and a length of approximately 23 inches. As such, the body 314 can have a volume of approximately 296 cubic centimeters, given by Equation (1): ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ = ^^ ^^2ℎ Equation (1)
volume of the cylinder; ^^ is the radius of the cylinder; and ℎ is the length of the cylinder. [110] The feedstock 302 can be pumped at a rate of approximately 0.89 milliliters per second (mL/s). Based on the volume of the body 314, it can take approximately 333 seconds for the feedstock 102 to travel through the body 314, that is, to enter from the
lower end of the body 314 and exit from the upper end of the body 314. Initially, the pump 112 and the electrical generator 320 can operate to reach a steady state of operation within the heating chamber 310 in respect of volume and temperature. [111] During steady state operation, the electrical generator 320 having a power of approximately 400 Watts (W) can add enthalpy to the heating chamber 310 at a rate of approximately 1.35 Joules per cubic centimeters per second (J/cc/s), given by Equation (2): ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ℎ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ = ^^ ^^ ^^ ^^ ^^ ^^ Equation (2) [112]
each cubic centimeter of feedstock can absorb approximately 449 Joules as it travels from the bottom to the top of the body 314, given by Equation (3): ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ = ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ × ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ ^^ Equation (3) [113] In some embodiments with brine as the feedstock 302, during steady state operation, the temperature at the lower end 408c of the body 314 can be approximately 83°C, and the temperature at the upper end 408h of the body 314 can be approximately 115°C. This temperature difference indicates that 32W of enthalpy can be added to every cubic centimeter of feedstock 302. In some embodiments, there can also be heat loss through the outer surface of the body 314 to the ambient environment. [114] Nonetheless, out of the heat absorbed per unit, approximately 400 Joules per cubic centimeter can remain for the latent heat of vaporization. For water, the latent heat of vaporization can be approximately 2260 Joules per cubic centimeter at 1 bar. The ratio of 400 J/cc to 2260 J/cc means that about 17% of the water can be converted to steam. [115] It should be noted that the pressure of the body 314 can be higher than 1 bar. With a higher pressure, the latent heat of vaporization could be even greater. However, the latent heat of vaporization of brine is known to be lower than that of distilled water. In brine, the presence of ions, such as sodium and chloride ions, can disrupt the hydrogen bonding between water molecules and weaken the intermolecular forces, resulting in a lower latent heat of vaporization compared to that of distilled water. As a result, brine can require less energy to vaporize than pure water.
[116] Referring now to FIG. 4, shown therein is another illustration 400 of the example heating chamber 310 of FIG.3. As shown in FIG.4, the electrical generator 320 applies a current 324 to the feedstock 302 within the body 314. [117] In some embodiments, the conductivity of the feedstock 302 can be considered substantially same, or uniform, throughout the body 314. In some embodiments, the density of the feedstock 302 can also be considered substantially same, or uniform as it percolates upwards through the body 314. When the conductivity of the feedstock 302 and the density of the feedstock are both uniform throughout the body 314, the I2R dissipation will also be substantially uniform throughout the body 314. [118] By using a vertically elongated body 314 with a non-turbulent fluid flow, the feedstock 302 can get progressively hotter as it rises higher in the body 314. Only at the upper end of the body 314, the feedstock 302 can be at a maximum temperature. In such cases, the temperature of the feedstock 302 at 408x can be determined using Equation (4): ^^ ^^ ^^ = ^^ ^^ + ^^ ( ^^ℎ− ^^ ^^ ) Equation (4) where ^^ is the height of the tube at 408x; ^^ is the length of the tube; ^^ ^^ is the temperature of the feedstock at the lower end 408c of the body; and ^^ℎ is the temperature of the feedstock at the upper end 408h of the body. [119] Generally, after reaching steady state operation, the temperature of the feedstock 302 at the lower end 408c of the body 314 can be relatively colder than the temperature of the feedstock 302 at the upper end 408h of the body 314. For example, in some embodiments, the temperature of the feedstock 302 at the lower end 408c of the body 314 can be 83°C while the temperature of the feedstock 302 at the upper end 408h of the body 314 can be 115°C. Furthermore, the relative temperature difference can remain the same through continued operation after steady state. [120] As shown in FIG.4, steam bubbles 406 can form near the upper end 408h of the body 314. The formation of steam bubbles 406 can depend on the target
temperature and the pressure of the heating chamber 310. The formation of steam bubbles 406 can expand the specific volume of the feedstock fluid 302. [121] If steam bubbles form near the upper end 408h of the body 314, the velocity of the feedstock fluid 302 near the upper end 408h of the body 314 can increase. The higher velocity can be advantageous as it results in the feedstock fluid 302 being subject to the hotter temperature of the upper end 408h for a shorter time. Steam bubbles 406 can also increase local electrical resistance near the upper end 408h of the body 314, resulting in a higher rate of heating. The higher rate of heating can be advantageous as the feedstock 302 dwells at the hotter temperature for less time. [122] In some embodiments, the feedstock 302 can be temperature-sensitive and degrade when exposed to elevated temperatures for a certain duration. For example, many foods, such as proteins, can be temperature-sensitive. As such, heating with minimal time spent at elevated temperatures can be advantageous. [123] Furthermore, immediately after getting to the maximum temperature at the upper end of the body 314, the feedstock 302 passes through the expansion valve 116, experiences a sudden drop in pressure, and then enters the separator 118. This can release more vapor and quickly cool the feedstock 302. Cooling of the feedstock 302 can also be advantageous as it reduces the time spent at elevated temperatures. [124] In some embodiments, the conductivity of the feedstock 302 can vary during the heating process. For example, the electrical conductivity of the feedstock 302 can increase with hotter temperatures due to the increased mobility of ions within the feedstock 302. As a further example, the current can increase by a factor of two when the feedstock 302 is heated from about 30°C to 115°C. In some embodiments, the higher electrical conductivity of the feedstock 302 can offset the greater electrical resistance near the upper end 408h of the body 314 due to steam bubbles 406. [125] In some embodiments, the shape of the vertically elongated body can be used to shape the heating profile of the feedstock 302 along the length of the heating chamber 310. Referring now to FIG. 5, shown therein is an illustration 500 of another example heating chamber 510 for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to heating chambers 110, 310, heating chamber 510 can include a vertically elongated body 514 and a plurality of electrodes (not shown in
FIG.5). An electrical generator 520, similar to electrical generators 120, 320 can excite the plurality of electrodes to cause conduction and heat the feedstock 502 volumetrically. [126] Similar to body 314, the body 514 can be formed of a dielectric, non- conductive material. Further, the outer surface of the body 514 can be thermally insulated. As shown in FIG.5, the diameter of the body 514 can vary along the length of the body 514. In particular, the diameter of the upper portion of the body 514U is smaller than the diameter of the lower portion of the body 514L. [127] Generally, the electrical resistance can be a function of the cross-sectional area of the body 514. Further, heat dissipation can also depend on the electrical resistance, as well as the cross-sectional area of the body 514 and the flow rate of the feedstock 502. Hence, heating in different areas along the length of the body 514 can be targeted by adjusting the cross-section of the body 514 along its length, such as but not limited to an axial dimension of the body 514 (e.g., a diameter of a tubular body). For example, more heat can be transferred in the upper portion of the body 514U than the heat transferred in the lower portion of the body 514L. That is, the rate of temperature rise in the upper portion of the body 514U can be higher than the rate of temperature rise in the lower portion of the body 514L. The higher rate of temperature rise can also additionally increase the velocity of the fluid 502. [128] Generally, the volume of feedstock 502 that is being heated along a portion of the body 514 can be proportional to the cross-sectional area of that portion of the body 514. As such, the volume of feedstock 502 that is being heated along the lower portion of the body 514L is greater than the volume of feedstock 502 that is being heated along the upper portion of the body 514U. [129] However, the overall flow rate along the length of the body 514 can remain constant between the upper portion of the body 514U and the lower portion of the body 514L. Along the length of the body 314, the current can be substantially uniform. [130] Referring now to FIG. 6, shown therein is an illustration 600 of another example heating chamber 610 for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to heating chambers 110, 310, 510, heating chamber 610 can include a vertically elongated body 614. As shown in FIG.6, expansion valve 616 and separator 618 are integrated with the vertically elongated body 614.
[131] Similar to body 314, 514, the body 614 can be formed of a dielectric, non- conductive material. Further, the outer surface of the body 614 can be thermally insulated. Also, the diameter of the upper portion of the body 614 is smaller than the diameter of the lower portion of the body 614. As shown in FIG.6, when the upper end of the body 614 has a small diameter, the inlet of the expansion valve 616 can be coupled thereto. [132] In some embodiments, the expansion valve 616 can act as an electrode. In particular, the inlet of the expansion valve 616 can serve as an upper electrode of the plurality of electrodes. Thus, the electrical generator 620, which is similar to electrical generators 120, 320, 520, can be electrically connected to expansion valve 616 and lower electrode 622b, which is similar to lower electrode 322b. Excitation of the upper electrode 616 and lower electrode 622b can cause conduction and heat the feedstock volumetrically. [133] After the feedstock is heated, the fluid exits the upper end of the body 614 and passes through the expansion valve 616. Similar to expansion valve 116, the expansion valve 616 is operable to reduce the pressure of the fluid and causes vapor to flash off from the fluid. [134] The separator 618 is downstream of the expansion valve 116. As shown in FIG.6, the separator 618 can adjoin the expansion valve 616, in some embodiments. In particular, the outlet of the expansion valve 616 can be coupled to the separator 618. Thus, immediately after the expansion valve 616, the heating chamber 610 widens to the separator 618. The wider cross-section of the separator 618 allows vapor 606 from the fluid to rise. [135] In some embodiments, the separator 618 includes an upper outlet 618U and a lower outlet 618L. The upper outlet 618U can be configured to receive vapor 606 that rises from the fluid. As shown in FIG. 6, the upper outlet 618U can be positioned within the upper portion of the separator 618. Vapor 606 that rises from the fluid can enter the upper outlet 618U. [136] The lower outlet 618L can be configured to receive liquid from the fluid. As shown in FIG.6, the lower outlet 618L can be positioned around the lower portion of the separator 618. Heated liquid 608 from the fluid can flow into the lower outlet 618L. Thus, the vapor 606 and the heated liquid 608 can be separated within the separator 618.
[137] Referring now to FIG.7, shown therein is an illustration 700 of a portion of another example heating chamber 710 for the heating system 100 of FIG. 1, in accordance with an example embodiment. Heating chamber 710 includes a vertically elongated body 714. [138] Similar to body 614, body 714 can be formed of a dielectric, non-conductive material. In some embodiments, the outer surface of body 714 can be thermally insulated. Furthermore, body 714 can be formed of an elastic material. A toroidal actuator, such as toroidal actuator 714T, can be coupled to a portion of the body 714. As shown in FIG.7, toroidal actuator 714T can be coupled to a neck of the body 714. The toroidal actuator 714T can be operated to adjust the diameter of the portion of the body 714 to which it is coupled. That is, the toroidal actuator 714T can compress to constrict the diameter of the body 714 and loosen to not constrict the diameter of the body 714. The toroidal actuator 714T can provide a mechanism to control the diameter of the body 714. In some embodiments, the toroidal actuator 714T can be controlled based on the temperature of the feedstock within the body 714. [139] The toroidal actuator 714T is shown in FIG.7 for illustrative purposes only. A toroidal actuator 714T can be coupled to other portions of a vertically elongated body 714. For example, toroidal actuator 714T can be a lower portion of a vertically elongated body 714. As well, the vertically elongated body 714 shown in FIG.7 is shown as being integrated with expansion valve 716 and separator 718. In other embodiments, a toroidal actuator 714T can be coupled to a vertically elongated body 714 that is not integrated with an expansion valve 716 and a separator 718. [140] Referring now to FIG.8, shown therein is an illustration 800 of an example electrode 822 of another example heating chamber for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to electrodes 322, 622b, electrode 822 can define a passage 826 therein. Feedstock can flow through the passage 826. [141] As shown in FIG. 8, the inner surface of the electrode 822 that forms a passage can include a plurality of protrusions 828, in some embodiments. The protrusions 828 can increase the surface area of the electrode 822 that is in contact with the feedstock. Thus, the plurality of protrusions 828 improve conduction of the feedstock compared to a passage having a flat surface.
[142] Although electrode 822 is shown as being an upper electrode with the body 814 coupled to the lower portion of electrode 822, protrusions 828 can also be provided any electrode of the plurality of electrodes, such as lower electrodes 322b, 622b. Furthermore, protrusions 828 can be provided on other electrode configurations, including but not limited to coaxial electrodes and parallel plate electrodes. [143] Referring now to FIG. 9, shown therein is an illustration 900 of another example heating chamber 910 for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to heating chambers 110, 310, 510, 610, 710, heating chamber 910 can include a vertically elongated body 914 and a plurality of electrodes 922. An electrical generator 920, similar to electrical generators 120, 320, 520, 620, can excite the plurality of electrodes 922 to cause conduction and heat the feedstock 502 volumetrically. [144] Similar to body 314, 514, 614, 714, 814, the body 914 can be formed of a dielectric, non-conductive material. Further, the outer surface of the body 914 can be thermally insulated. As shown in FIG.9, the diameter of the body 914 can vary along the length of the body 914. In particular, the diameter of the upper portion of the body 914 is smaller than the diameter of the lower portion of the body 914. [145] With a smaller diameter in the lower portion of the body 914, the most intense heating can occur in the lower portion of the body 914. This smaller diameter in the lower portion of the body 914 can accelerate the heating of the feedstock. [146] As the feedstock moves upward through the increasing diameter of the body 914, the electrical resistance decrease. With lower electrical resistance, the heat produced in the upper portion of the body 914 can be less than the heat produced in the lower portion of the body 914. Furthermore, a greater volume of feedstock in the upper portion of the body 914 will be subjected to the heat produced in the upper portion of the body 914. As such, the rate of heat transfer can be lower in the upper portion of the body 914 than the rate of heat transfer in the lower portion of the body 914. The lower rate of heat transfer can be advantageous is allowing for more precise control of the temperature at the upper end of the body 914. More precise control of the temperature at the upper end of the body 914 can allow for a higher temperature range for the heated feedstock.
[147] In some embodiments, the upper electrode 922a having a larger diameter than the lower electrode 922b can better ensure electrical contact in the event that steam bubbles 406 form at the upper end of the body 914. Steam bubbles can cause a potential electrical discontinuity. [148] Referring now to FIG. 10A, shown therein is an electrical representation 1000 of an example heating chamber for the heating system 100 of FIG.1, in accordance with an example embodiment. Heating chamber 1010 can include a vertically elongated body 1014 and a plurality of electrodes 1022a, 1022b (herein collectively referred to as the plurality of electrodes 1022). Similar to body 314, the body 1014 can be formed of a dielectric, non-conductive material. Further, the outer surface of the body 1014 can be thermally insulated. As shown in FIG.10A, the body 1014 can be tubular and the diameter of the body 1014 can be substantially uniform or constant along the length of the body 1014, similar to that of 314. An electrical generator 1020, similar to electrical generators 120, 320, 520, 620, 920 can excite the plurality of electrodes 1022 to cause conduction and heat the feedstock within the vertically elongated body 1014 volumetrically. [149] As described above, the transfer of heat energy to the feedstock within the heating chamber 1010 results from I2R dissipation. Accordingly, an electrical representation of the heating chamber 1010 is shown in FIG. 10A, in which R is the equivalent electrical resistance between the upper electrode 1022a and the lower electrode 1022b. [150] The plurality of electrodes 1022 are excited using an alternating current to avoid electrochemistry at the plurality of electrodes 1022. Electrochemistry can include, but is not limited to, electrolysis of water, which can occur when direct current is applied to the plurality of electrodes 1022. Electrolysis can generate hydrogen and/or oxygen, which is generally undesirable. In some embodiments, gases produced by any electrochemistry, such as hydrogen and oxygen, can be collected from the separator 118. Excitation of the plurality of electrodes 1022 with a frequency in the order of a hundred hertz (Hz) can be sufficient for avoiding electrochemistry. [151] However, the upper electrode 1022a being hotter than the lower electrode 1022b can lead to a difference in the thermionic emission of the plurality of electrodes 1022. The difference in thermionic emission can create a weak diode effect, leading to
rectification of the alternating current across the upper electrode 1022a. An electrical representation 1050 of the heating chamber 1010 with the diode effect (D) is shown in FIG.10B. [152] With the diode effect, the current can be slightly larger in the forward direction of the diode than the reverse direction of the diode. The difference in current can lead to electrochemistry at the plurality of electrodes 1022. Electrochemistry can liberate hydrogen. Electrochemistry can also alter the chemistry of the feedstock. [153] To avoid rectification, the electrical generator can be capacitively coupled, as shown in the electrical representation 1100 of FIG.11, in accordance with an example embodiment. Heating chamber 1110 can include a vertically elongated body 1114 and a plurality of electrodes 1122a, 1122b (herein collectively referred to as the plurality of electrodes 1122). Similar to body 314, 1014, the body 1114 can be formed of a dielectric, non-conductive material. Further, the outer surface of the body 1114 can be thermally insulated. As shown in FIG.11, the body 1114 can be tubular and the diameter of the body 1114 can be substantially uniform or constant along the length of the body 1114, similar to that of 314, 1014. An electrical generator 1120, similar to electrical generators 120, 320, 520, 620, 920, 1020 can excite the plurality of electrodes 1122 to cause conduction and heat the feedstock within the vertically elongated body 1114 volumetrically. [154] A capacitor (C) can be connected in series between the upper electrode 1122a and the electrical generator 1120 and build up a small DC voltage. The capacitor (C) can then self-adapt to the rectification. The capacity of the capacitor (C) can be selected based on the frequency of the excitation applied to the plurality of electrodes. A small-valued capacitor (C) can be sufficient for a fairly high frequency of excitation. [155] In some embodiments, a DC current source can be coupled to the upper electrode 1122a to compensate for the rectification. The DC current source can apply a DC current in the opposite direction to the rectified current to compensate for the rectification. [156] In some embodiments, the material forming the plurality of electrodes 1122 can be selected to limit or minimize the difference in the thermionic emissions of the plurality of electrodes 1122. For example, the colder electrode, such as the lower
electrode 1122b, can be formed of a material having a higher resistivity than the hotter electrode, such as the upper electrode 1122a, to limit the temperature gradient between the plurality of electrodes 1122. As a further example, the colder electrode 1122b can be formed of an alloy. In some embodiments, the material forming the plurality of electrodes 1122 can be selected to not interact with the heating process. That is, the material that is non-reactive to alternating current can be selected to form the plurality of electrodes 1122. For example, aluminum can oxidize at low AC frequencies and result in rectification and is unlikely to be selected. [157] In some embodiments, the difference in the thermionic emission of the plurality of electrodes 1122 can be limited or reduced by heating the colder electrode 1122b. For example, the colder electrode 1122b can be heated resistively by running a current through the electrode 1122b. In some embodiments, a DC current source can be coupled to the colder electrode 1122b to heat the colder electrode 1122b and reduce the temperature gradient between the plurality of electrodes 1122. The magnitude of the current to be compensated for can be determined by first measuring the average DC current that results from the diode effect. [158] Referring now to FIG.12, shown therein is an illustration 1200 of current crowding occurring in an example heating chamber 1210 for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to heating chambers 110, 310, 510, 610, 710, 910, 1010, 1110, heating chamber 1210 can include a vertically elongated body 1214 and a plurality of electrodes 1222a, 1222b (herein collectively referred to as the plurality of electrodes 1222). An electrical generator 1220, similar to electrical generators 120, 320, 520, 620, 720, 920, 1020, 1120 can excite the plurality of electrodes 1222 to cause conduction and heat the feedstock volumetrically. [159] Similar to body 314, the body 1214 can be formed of a dielectric, non- conductive material. As shown in FIG.12, the body 1214 can be tubular and the diameter of the body 1214 can be substantially uniform or constant along the length of the body 1214, similar to that of 314, 1014, and 1114. The outer surface of the body 1214 can be thermally insulated with RF transparent material on the body 1214. [160] In some embodiments, a temperature gradient can form across the cross- section of the body 1214. Despite insulation being provided on the outer surface of the
body 1214, the outer wall of the body 1214 can be cooler as there is no I2R heating beyond the body 1214. [161] A temperature gradient can also occur due to current crowding. Current crowding refers to the phenomenon in which current 1224 is higher in the center portion than the portion 1224p around the perimeter of the body 1214, that is the outer sides of the body 1214. When a DC current travels through a homogeneous resistive medium, the current 1224 can crowd slightly in the center of the body 1214. That is, the current density can be greater in the center portion than the outer sides 1224p of the body 1214. The magnetic field generated by conduction can cause a Lorentz force. [162] In some embodiments with currents having a small magnitude, the Lorentz force can be weak. Furthermore, the Lorentz force can be countered by electrostatic forces as current crowding 1224 can lead to radial potential variation. As such, current crowding 1224 can be negligible with currents having a small magnitude. For example, current crowding 1224 can be negligible with currents less than 1 Amperes (A). [163] In some embodiments, the current density being greater in the center than the outer sides 1224p of the body 1214 can lead to increased local heating in the center. Increased local heating in the center can increase the electrical conductivity, which in turn, further increases current crowding 1224. The positive feedback loop of current crowding can be limited by the diffusion and convection currents of the ions. Current crowding can lead to the center portion of the body 1214 being hotter than the outer sides 1224p of the body 1214, which is undesirable. [164] In some embodiments, the plurality of electrodes 1222 can be excited with a higher frequency. The magnetic field can change with time, resulting in the generation of electric fields and eddy currents. Eddy currents can reinforce the current 1224 to the outer sides 1224p of the body 1214 and reduce the current 1224 in the center portion of the body 1214. The effect of a higher frequency can also be understood as a skin effect. That is, the feedstock can act as an electrical conductor and a higher frequency can cause current 1224 to flow toward the outer sides 1224p of the electrical conductor. Increasing the current density 1224 at the outer sides 1224p of the body 1214 can help warm the outer sides 1224p of the body 1214. Thus, exciting the plurality of electrodes 1222 with a
higher frequency can reduce the temperature gradient across the cross-section of the body 1214. [165] In some embodiments, the body 1214 can be shaped to have a geometry that avoids or limits current crowding. For example, a larger diameter can allow for current crowding. As such, the diameter of the body 1214 can be smaller to avoid current crowding. Furthermore, other shapes to avoid current crowding is possible. [166] In some embodiments, the temperature and/or heating profile of the heating chamber 1210 can be controlled by, both the shape of the body 1214 and selecting an appropriate frequency. In some embodiments, a uniform temperature can be desirable. In some embodiments, a patterned temperature can be desirable. [167] Returning now to FIG. 1, with the feedstock 102 acting as an electrical conductor, a closed electric circuit can be formed by the liquid flow path outside of the heating chamber 110. That is, electrical current can flow outside of the heating chamber 110, namely beyond the plurality of electrodes. Electrical current outside of the heating chamber 110 can lead to inefficiencies (e.g., energy loss), stray currents and voltages in the system 100 posing electrical hazards, and be undesirable. [168] Referring now to FIG.13, shown therein is an illustration 1300 of another example heating chamber 1310 for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to heating chambers 110, 310, 510, 610, 710, 910, 1010, 1110, 1210, heating chamber 1310 can include a vertically elongated body 1314 and a plurality of electrodes 1322. An electrical generator 1320, similar to electrical generators 120, 320, 520, 620, 720, 920, 1020, 1120, 1220 can excite the plurality of electrodes 1322 to cause conduction and heat the feedstock volumetrically. [169] As shown in FIG. 13, the heating chamber 1310 can include an upper portion 1314a and a lower portion 1314b. An intermediate electrode 1322b can be coupled between the upper portion 1314a and the lower portion 1314b. That is, the intermediate electrode 1322b can be positioned along the vertically elongated body 1314 and between the upper electrode 1322a and lower electrode 1322c at opposite ends of the body 1314. Similar to the upper and lower electrodes 1322a, 1322c, the intermediate electrode 1322b can also form a passage through which the feedstock 1302 or the fluid 1304 passes.
[170] In some embodiments, the upper and lower electrodes 1322a, 1322c can be grounded and the intermediate electrode 1322b can be coupled to the electrical generator 1320. This configuration forms two closed loops for the electrical current 1324a, 1324b. Thus, this configuration can help constrain the electrical current 1324a, 1324b within the heating chamber 1310. The intermediate electrode 1322b can also help control the heating profile along the length of the elongated body 1314. [171] Although only two heating chamber portions 1314a, 1314b are shown in FIG.13, the heating chamber 1310 can include fewer or more heating chamber portions 1314. Likewise, although only three electrodes 1322a, 1322b, 1322c are shown in FIG. 13, the heating chamber 1310 can include fewer or more electrodes 1322. Further, although only one electrical generator 1320 is shown in FIG. 13, the heating chamber 1310 can be coupled to more electrical generators 1320. [172] Referring now to FIG.14, shown therein is an illustration 1400 of another example heating chamber 1410 for the heating system 100 of FIG.1, in accordance with an example embodiment. Similar to heating chambers 110, 310, 510, 610, 710, 910, 1010, 1110, 1210, 1310, heating chamber 1410 can include a vertically elongated body 1414 and a plurality of electrodes 1422. A plurality of electrical generators 1420a, 1420b, 1420c (herein collectively referred to as electrical generators 1420) similar to electrical generators 120, 320, 520, 620, 720, 920, 1020, 1120, 1220, 1320 can excite the plurality of electrodes 1422 to cause conduction and heat the feedstock volumetrically. [173] As shown in FIG. 14, the heating chamber 1410 can include an upper portion 1414a, a lower portion 1414f, and a plurality of intermediate portions 1414b, 1414c, 1414d, 1414e. Similar to heating chamber 1310, a plurality of intermediate electrodes 1422b, 1422c, 1422d, 1422e, 1422f, 1422g can be coupled between the upper portion 1414a and the lower portion 1414f. That is, the intermediate electrodes 1422b, 1422c, 1422d, 1422e, 1422f, 1422g can be positioned along the vertically elongated body 1414 and between the upper electrode 1422a and lower electrode 1422c at opposite ends of the body 1414. Similar to the upper and lower electrodes 1422a, 1422c, the intermediate electrodes 1422b, 1422c, 1422d, 1422e, 1422f, 1422g can also form a passage through which the feedstock 1402 or the fluid 1404 passes.
[174] As shown in FIG. 14, the upper and lower electrodes 1422a, 1422g and intermediate electrodes 1422c, 1422e can be grounded while intermediate electrodes 1422b, 1422d, and 1422f can be coupled to the electrical generators 1420. Similar to heating chamber 1310, this configuration can help constrain the electrical current within the heating chamber 1410. Furthermore, with additional intermediate electrodes, the heating profile along the length of the elongated body 1414 can be more finely controlled and adjusted. In some embodiments, the electrodes 1422 can be excited with different frequencies to adjust the shape of heat distribution in the heating chamber 1410. Furthermore, the frequency of the alternating current applied to the electrodes 1422 can vary with time. For example, different frequencies can used depending on the electrical resistance of the feedstock 1402, which can vary with temperature. [175] Although six heating chamber portions 1414a, 1414b, 1414c, 1414d, 1414e, 1414f are shown in FIG.14, the heating chamber 1410 can include fewer or more heating chamber portions 1414. Likewise, although seven electrodes 1422a, 1422b, 1422c, 1422d, 1422e, 1422f, 1422g are shown in FIG.14, the heating chamber 1410 can include fewer or more electrodes 1422. Further, although three electrical generators 1420a, 1420b, 1420c are shown in FIG.14, the heating chamber 1410 can be coupled to fewer or more electrical generators 1420. In some embodiments, an electrical generator 1420 can provide a plurality of outputs. For example, the plurality of outputs can be obtained from different transformers of the electrical generator 1420 or different taps from a multi-tap transformer connected to the electrical generator 1420. [176] Referring now to FIG.15, shown therein is an illustration 1500 of example components of the heating system 100 of FIG. 1, in accordance with an example embodiment. Similar to heating chambers 110, 310, 510, 610, 710, 910, 1010, 1110, 1210, 1310, 1410, heating chamber 1510 can include a vertically elongated body 1514 and a plurality of electrodes 1522a, 1522b (herein collectively referred to as the plurality of electrodes 1522). [177] Similar to body 314, 514, 614, 714, 914, 1014, 1114, 1214, 1314, 1414, vertically elongated body 1514 can be formed of a dielectric, non-conductive material. Further, the outer surface of the body 1514 can be thermally insulated. Similar to expansion valve 616 and separator 618 of FIG.6, expansion valve 1516 and separator
1518 are integrated with the vertically elongated body 1510. An electrical generator 1520, similar to electrical generators 120, 320, 520, 620, 720, 920, 1020, 1120, 1220, 1320, 1420 can excite the plurality of electrodes 1522 to cause conduction and heat the feedstock volumetrically. The heated liquid 1508 can be returned to pump 1512 to be recirculated. [178] In some embodiments, the separator 1518 can be configured to break the closed electrical circuit formed by the liquid flow path outside of the heating chamber 1510. The separator 1518 can be formed of non-conductive materials. In addition, the separator 1518 can be grounded to constrain the electrical current within the heating chamber 1510. [179] Similar to separator 618, separator 1518 includes an upper outlet 1518U and a lower outlet 1518L. The upper outlet 1518U can be configured to receive vapor 1506 that rises from the fluid. The lower outlet 1518L can be configured to receive liquid from the fluid. [180] As shown in FIG. 15, heated liquid 1508 from the fluid can flow into the lower outlet 1518L and to a return orifice 1532. The return orifice 1532 can force the heated liquid 1508 into an air chamber 1536 in the form of droplets 1534. That is, return orifice 1532 can generate droplets 1534 from the heated liquid 1508, which can break the electrical circuit in the liquid flow path before the heated liquid 1508 returns to pump 1512. In the example shown in FIG. 15, the separator 1518 generates droplets 1534 in a separately from the separation of vapor 1506 and liquid 1508. In other embodiments, the separator 1518 can generate droplets 1534 in the same chamber as that in which vapor 1506 and liquid 1508 are separated. [181] Referring now to FIG.16, shown therein is an illustration 1600 of example components of heating system 100 of FIG. 1, in accordance with another example embodiment. As shown in FIG.16, a heating stage 1630 can include a feedstock supply tank having feedstock 1602 that is pumped by pump 1612 into a vertically elongated body 1614 of a heating chamber 1610. In the heating chamber, the feedstock 1602 can be heated to a fluid by electrical generator 1620 exciting electrodes 1622a, 1622b coupled to the body 1614. The fluid can flow to an expansion valve 1616 and a separator 1618.
The expansion valve 1616 can cause vapor 1606 to flash off the heated liquid 1608. The separator 1618 can divert the vapor 1606 away from the heated liquid 1608. [182] In some embodiments, heat can be recovered from the heated liquid 1608 and/or the vapor 1606 to reduce overall energy use of the system 100. As shown in FIG. 16, the heated liquid 1608 can flow from the separator 1618 to a heat exchanger 1640 before it returns to the feedstock 1602 supply tank. The heat recovered from the heated liquid 1608 can be used to preheat the feedstock 1602 before it is heated in the heating chamber 1610 within the same heating stage. In some embodiments, the heat recovered from the heated liquid 1608 can be used to preheat the feedstock 1602 of another heating stage 1630. In some embodiments, each heating stage 1630 can have a frequency, voltage, temperature, and/or flow rate that is optimized for that stage. [183] As shown in FIG.16, the vapor 1606 can flow from the separator 1618 to a heat exchanger 1642. The vapor 1606 becomes condensate after being cooled in the heat exchanger 1642 and can be collected in a condensate tank 1644. The heat recovered from the vapor 1606 can be used to preheat the feedstock 1602 before it is heated in the heating chamber 1610. [184] Referring now to FIG.17, shown therein is an illustration 1700 of example components of heating system 100 of FIG. 1, in accordance with another example embodiment. As shown in FIG.17, a heating stage 1730 can include a feedstock supply tank having feedstock 1702 that is pumped by pump 1712 into a vertically elongated body 1714 of a heating chamber 1710. In the heating chamber, the feedstock 1702 can be heated to a fluid by electrical generator 1720. The fluid can flow to an expansion valve 1716 and a separator 1718. The expansion valve 1716 can cause vapor 1706 to flash off the heated liquid 1708. The separator 1718 diverts the vapor 1706 away from the heated liquid 1708. [185] Similar to separator 1518, separator 1718 can form droplets 1734 from the heated liquid 1708. In particular, separator 1718 can force the heated liquid 1708 through a spray tube 1732 to generate droplets 1734 to reduce any electrical current in the feedstock 1702 outside of the heating chamber 1710. After the separator 1718, the heated liquid 1708 can flow to another heating stage, similar to heating stage 1730.
[186] Referring now to FIG.18, shown therein is an illustration 1800 of example components of heating system 100 of FIG. 1, in accordance with another example embodiment. As shown in FIG.18, a heating stage 1830 can include a feedstock supply tank having feedstock 1802 that is pumped by pump 1812 into a vertically elongated body 1814 of a heating chamber 1810. In the heating chamber 1810, the feedstock 1802 can be heated to a fluid by electrical generator 1820 exciting electrodes 1822a, 1822b coupled to the body 1814. The fluid can flow to an expansion valve 1816 and a separator 1818. The expansion valve 1816 can cause vapor 1806 to flash off the heated liquid 1808. The separator 1818 can divert the vapor 1806 away from the heated liquid 1808. Similar to separators 1518, 1718, the separator 1818 can include a spray tube 1832 to form droplets 1834 from the heated liquid 1808. [187] As shown in FIG.18, a vacuum system 150, including a vacuum pump 1852 and a level control valve 1854, can be used to adjust the pressure of the feedstock 1802 and thereby the overall system pressure to an initial pressure (Pi). The vacuum pump 1852 can draw gas 1856 out of the feedstock supply. In some embodiments, the vacuum pump 1852 and level control valve 1854 can reduce the ambient pressure of the feedstock 1802 to the initial pressure (Pi) so that the boiling point can be at a lower temperature than the ambient pressure. For example, when the ambient pressure is atmospheric pressure, the vacuum system 150 can reduce the overall system pressure to be less than 100 kPa. Some types of feedstock 1802 can be temperature-sensitive and degrade at a particular temperature. For example, many foods can be temperature-sensitive. Further, plant-based proteins can degrade at a temperature of approximately 60°C. By using an initial pressure (Pi) that is lower than the ambient pressure, degradation of the feedstock 1802 can be avoided. Continuing with the example of plant-based proteins as a feedstock, by lowering the initial pressure (Pi) of the feedstock to less than the ambient pressure, the plant-based protein can boil at a temperature lower than 60°C. [188] In some embodiments, the heating system 100 can include a control system (not shown in FIG. 1). The control system can operate to control and/or monitor the operation of the heating system 100. In some embodiments, the heating system 100 can include fewer or more control systems. For example, one or more control systems can be dedicated to one or more heating stages.
[189] The control system can include control interfaces that allow a user to configure the heating system 100. In some embodiments, the control system can select control parameters for the heating system, such as the control parameters for the vacuum system 1850, the pump 112 and/or the electrical generator 120, including but not limited to the initial pressure (Pi), the flow rate, the maximum temperature of the body 114, the waveform, the magnitude, and/or the frequency of the output of the electrical generator 120. In some embodiments, the control parameters can be determined by the control system. For example, the control parameters can be determined based on the physical properties of the body 114, including the length of the body 114, the cross-sectional area of the body, a desire heating profile along the length of the body 114, or the conductivity of the feedstock 102, which can vary depending on the progress of the heating process. [190] The control system can include a processor, a storage component, and/or a communication component. The processor can control the operation of the control system. The processor can include any suitable processors, controllers, digital signal processors, graphics processing units, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), microcontrollers, and/or other suitably programmed or programmable logic circuits that can provide sufficient processing power depending on the configuration, purposes and requirements of the control system. In some embodiments, the processor can include more than one processor with each processor being configured to perform different dedicated tasks. [191] The storage component can include RAM, ROM, one or more hard drives, one or more flash drives or some other suitable data storage elements such as disk drives. For example, the storage component can include volatile and non-volatile memory. Non-volatile memory can store computer programs consisting of computer- executable instructions, which can be loaded into the volatile memory for execution by the processor. Operating the processor to carry out a function can involve executing instructions (e.g., a software program) that can be stored in the storage component and/or transmitting or receiving inputs and outputs via the communication component. The storage component can also store data input to, or output from, the processor, which can result from the course of executing the computer-executable instructions for example.
[192] The storage component can include one or more databases for storing data related to the heating system 100. The storage component can store data in respect of the operation of the heating system 100, such as data in respect of the heating stages, the vacuum system 1850, the pump 112, and/or the electrical generator 120. [193] The communication component can include any interface that enables the control system to communicate with various devices and other systems. For example, the communication component can facilitate communication with the other components of the heating system 100, such as the electrical generator 120, a system storage component, or instrumentation and control devices via the communication network. [194] In some embodiments, one or more computing devices can communicate with the heating system 100 via the communication network. A user may electronically configure the heating system 100 using the computing device. The computing device can include any device capable of communication with other devices through a network such as the communication network. The computing device can include a processor and memory, and may be an electronic tablet device, a personal computer, workstation, server, portable computer, mobile device, personal digital assistant, laptop, smart phone, Wireless Application Protocol (WAP) phone, and portable electronic devices or any combination of these. [195] Referring now to FIG.19, which is a flowchart of an example method 1900 for heating a feedstock in at least one heating stage. To assist with the description of method 1900, reference will be made simultaneously to FIGS.1 to 18. [196] Although the following description will refer to heating chamber 110, the heating chamber can be any heating chamber, such as heating chambers 310, 510, 610, 710, 910, 1010, 1110, 1210, 1310, 1410, 1510, 1610, 1710, or 1810. Although the following description will refer to electrodes 322, the electrodes can be any electrodes, such as electrodes 616, 622b, 716, 822, 922, 1022, 1122, 1222, 1322, 1422, or 1522. Furthermore, the following description refers to one heating stage but can apply to each heating stage. Any one or more of steps 1910 to 1950 for a heating stage can be performed simultaneously or successively with the performance of one or more steps of 1910 to 1950 for another heating stage.
[197] At 1910, a feedstock, such as feedstock 102, can be pumped into a lower portion 114L of a vertically elongated body 114. In some embodiments, a pump such as pump 112 can pump the feedstock 102 into the vertically elongated body 114. The feedstock 102 can include an electrically conductive liquid having an initial temperature (Ti) and an initial pressure (Pi). In some embodiments, at least one vacuum system such as vacuum system 1850 can be configured to control the initial temperature (Ti) and an initial pressure (Pi) of the feedstock 102. [198] At 1920, at least one alternating current can be applied to the feedstock 102 within the vertically elongated body 114 to heat the feedstock volumetrically to a saturation temperature (Ts) while the feedstock remains at the initial pressure (Pi). In some embodiments, an electrical generator, such as electrical generator 120 can apply the alternating current to the feedstock via a plurality of electrodes 322 coupled to the vertically elongated body 114. The feedstock 102 can be a fluid at the saturation temperature (Ts). [199] At 1930, the fluid can exit from an upper portion of the vertically elongated body 314 as the pump 112 continues to pump 112 feedstock 102 into the vertically elongated body 314. [200] At 1940, after the fluid has exited the vertically elongated body 314, the pressure of the fluid can be reduced from the initial pressure (Pi) to a lower pressure (Pl). In some embodiments, an expansion valve, such as expansion valve 116 can reduce the pressure of the fluid from the initial pressure (Pi) to the lower pressure (Pl). An example of this reduction in pressure is shown as line 210 of FIG.2A or line 224 of FIG.2B. The reduction in pressure can cause vapor 106 to flash off from the fluid and thereby dehydrate the feedstock 102. [201] At 1950, the vapor 106 can be separated from heated liquid 108 of the fluid. The heated liquid 108 can have a residual temperature that is higher than the initial temperature (Ti) and lower than the saturation temperature (Ts). In some embodiments, the heated liquid 108 can be recirculated through the same heating stage 130. In some embodiments, the heated liquid 108 can progress to another heating stage 130 to be furthered heated and/or dehydrated. In some embodiments, heat can be recovered from
the vapor 106 and/or the heated liquid 108 to preheat the feedstock 102 of the same heat stage 130 or the feedstock 102 of another heating stage 130. [202] It will be appreciated that numerous specific details are set forth in order to provide a thorough understanding of the example embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well- known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Furthermore, this description and the drawings are not to be considered as limiting the scope of the embodiments described herein in any way, but rather as merely describing the implementation of the various embodiments described herein. [203] It should be noted that terms of degree such as "substantially", "about" and "approximately" when used herein mean a reasonable amount of deviation of the modified term such that the end result is not significantly changed. These terms of degree should be construed as including a deviation of the modified term if this deviation would not negate the meaning of the term it modifies. [204] In addition, as used herein, the wording “and/or” is intended to represent an inclusive-or. That is, “X and/or Y” is intended to mean X or Y or both, for example. As a further example, “X, Y, and/or Z” is intended to mean X or Y or Z or any combination thereof. [205] It should be noted that the term “coupled” used herein indicates that two elements can be directly coupled to one another or coupled to one another through one or more intermediate elements. [206] The embodiments of the systems and methods described herein may be implemented in hardware or software, or a combination of both. These embodiments may be implemented in computer programs executing on programmable computers, each computer including at least one processor, a data storage system (including volatile memory or non-volatile memory or other data storage elements or a combination thereof), and at least one communication interface. For example and without limitation, the programmable computers (referred to below as computing devices) may be a server, network appliance, embedded device, computer expansion module, a personal computer,
laptop, personal data assistant, cellular telephone, smart-phone device, tablet computer, a wireless device or any other computing device capable of being configured to carry out the methods described herein. [207] In some embodiments, the communication interface may be a network communication interface. In embodiments in which elements are combined, the communication interface may be a software communication interface, such as those for inter-process communication (IPC). In still other embodiments, there may be a combination of communication interfaces implemented as hardware, software, and combination thereof. [208] Program code may be applied to input data to perform the functions described herein and to generate output information. The output information is applied to one or more output devices, in known fashion. [209] Each program may be implemented in a high level procedural or object oriented programming and/or scripting language, or both, to communicate with a computer system. However, the programs may be implemented in assembly or machine language, if desired. In any case, the language may be a compiled or interpreted language. Each such computer program may be stored on a storage media or a device (e.g., ROM, magnetic disk, optical disc) readable by a general or special purpose programmable computer, for configuring and operating the computer when the storage media or device is read by the computer to perform the procedures described herein. Embodiments of the system may also be considered to be implemented as a non- transitory computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner to perform the functions described herein. [210] Furthermore, the system, processes and methods of the described embodiments are capable of being distributed in a computer program product comprising a computer readable medium that bears computer usable instructions for one or more processors. The medium may be provided in various forms, including one or more diskettes, compact disks, tapes, chips, wireline transmissions, satellite transmissions, internet transmission or downloadings, magnetic and electronic storage media, digital and
analog signals, and the like. The computer useable instructions may also be in various forms, including compiled and non-compiled code. [211] Various embodiments have been described herein by way of example only. Various modification and variations may be made to these example embodiments without departing from the spirit and scope of the invention, which is limited only by the appended claims.
Claims
CLAIMS: 1. A system for heating a feedstock, the system comprising: - at least one heating stage, each heating stage comprising: o at least one pump for pumping the feedstock, the feedstock comprising a conductive liquid having an initial temperature and an initial pressure; o a heating chamber comprising a vertically elongated body and a plurality of electrodes coupled to the vertically elongated body, the vertically elongated body comprising an upper portion and a lower portion, the lower portion being configured to receive the pumped feedstock, the plurality of electrodes being operable to apply at least one alternating current to the feedstock within the vertically elongated body to heat the feedstock volumetrically to a saturation temperature while the feedstock remains at the initial pressure, the feedstock being a fluid at the saturation temperature; o an expansion valve downstream of the vertically elongated body, the expansion valve being operable to reduce a pressure of the fluid from the initial pressure to a lower pressure, the reduction in pressure causing vapor to flash off from the fluid; o a separator downstream of the expansion valve, the separator being configured to separate the vapor from heated liquid of the fluid, the heated liquid having a residual temperature that is higher than the initial temperature and lower than the saturation temperature; and o at least one electrical generator operable to excite the plurality of electrodes.
2. The system of claim 1, wherein, for one or more heating stages of the at least one heating stage, the plurality of electrodes comprise at least an upper electrode and a lower electrode positioned at opposite ends of the vertically elongated body, the lower electrode comprises a passage through which the feedstock passes, and the upper electrode comprises a passage through which the fluid passes.
3. The system of claim 2, further comprising, for the one or more heating stages of the at least one heating stage, at least one intermediate electrode positioned along the vertically elongated body and between the opposite ends, the at least one intermediate electrode comprising a passage through which at least a portion of the feedstock or the fluid passes.
4. The system of claim 3, wherein the at least one electrical generator is coupled one or more intermediate electrodes of the at least one intermediate electrode to control a heating profile of the feedstock within the heating chamber.
5. The system of any one of claims 3 or 4, wherein each of the upper electrode and the lower electrode is grounded.
6. The system of any one of claims 2 to 5, wherein the passage within each electrode of the plurality of electrodes comprise a plurality of protrusions to increase a surface area of the electrode that is in contact with the feedstock.
7. The system of any one of claims 2 to 6, further comprising a DC current source coupled to the upper electrode to compensate for rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode.
8. The system of any one of claims 2 to 6, further comprising a capacitor electrically connected in series between the upper electrode and the at least one electrical generator to avoid rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode.
9. The system of any one of claims 2 to 8, wherein the lower electrode is formed of a material having a higher resistivity than the upper electrode to minimize a temperature gradient between the upper electrode and the lower electrode.
10. The system of any one of claims 2 to 9, further comprising a DC current source coupled to the lower electrode to heat the lower electrode resistively to minimize a temperature gradient between the upper electrode and the lower electrode.
11. The system of any one of claims 2 to 10, wherein, for the one or more heating stages of the at least one heating stage, the vertically elongated body comprises a length and a cross-sectional area adapted to enable a desired heating profile along the length of the vertically elongated body.
12. The system of any one of claims 2 to 10, wherein, for the one or more heating stages of the at least one heating stage, the vertically elongated body comprises a tube having a uniform diameter along a length of the tube.
13. The system of any one of claims 2 to 10, wherein, for the one or more heating stages of the at least one heating stage, the vertically elongated body comprises a tube having a varying diameter along a length of the tube.
14. The system of claim 13, wherein, for the one or more heating stages of the at least one heating stage, the upper portion has a diameter that is smaller than a diameter of the lower portion to increase a velocity of the fluid.
15. The system of claim 14, wherein, for the one or more heating stages of the at least one heating stage, the expansion valve comprises an inlet formed by the upper electrode.
16. The system of any one of claims 14 or 15, wherein the expansion valve further comprises an outlet adjoined to the separator.
17. The system of any one of claims 14 or 16, wherein, for the one or more heating stages of the at least one heating stage, the separator comprises a return orifice
configured to allow the heated liquid to return to the at least one pump, thereby reducing electrical current outside of the vertically elongated body.
18. The system of claim 13, wherein, for the one or more heating stages of the at least one heating stage, the lower portion has a diameter that is smaller than a diameter of the upper portion to accelerate the heating of the feedstock.
19. The system of any one of claims 14 to 18, wherein, for the one or more heating stages of the at least one heating stage: - the vertically elongated body is formed of an elastic material; and - the system further comprises a toroidal actuator coupled to a portion of the vertically elongated body, the toroidal actuator being operable to adjust a diameter of the portion of the vertically elongated body.
20. The system of any one of claims 2 to 19, wherein, for the one or more heating stages of the at least one heating stage, the heating chamber further comprises insulation around at least the vertically elongated body to reduce heat loss, the insulation being formed of an RF-transparent material.
21. The system of claim 1, wherein, for one or more heating stages of the at least one heating stage, the plurality of electrodes comprise coaxial electrodes.
22. The system of claim 1, wherein, for one or more heating stages of the at least one heating stage, the plurality of electrodes comprise parallel plate electrodes.
23. The system of any one of claims 1 to 22, wherein for one or more heating stages of the at least one heating stage, the plurality of electrodes are formed of a material that is non-reactive to the alternating current.
24. The system of any one of claims 1 to 23, wherein, for one or more heating stages of the at least one heating stage, the at least one electrical generator is operable
to adjust one or more of a frequency or a voltage of each alternating current of the at least one alternating current.
25. The system of claim 24, further comprising a processor operable to adjust the at least one electrical generator based on one or more of a desired heating profile along a length of the vertically elongated body, a cross-sectional area of the vertically elongated body, or a conductivity of the feedstock.
26. The system of any one of claims 1 to 25, wherein, for one or more heating stages of the at least one heating stage, each electrical generator of the at least one electrical generator comprises at least one transformer for generating the at least one alternating current.
27. The system of any one of claims 1 to 26, wherein, for one or more heating stages of the at least one heating stage, the frequency of the alternating current is greater than 100 Hz.
28. The system of any one of claims 1 to 27, wherein, for one or more heating stages of the at least one heating stage, the at least one electrical generator comprise one or more of a radio frequency (RF) generator, an alternating current (AC) generator, a microwave generator, or a millimeter wave generator.
29. The system of any one of claims 1 to 28, further comprising, at least one heat exchanger for one or more heating stages of the at least one heating stage, the at least one heat exchanger being downstream of the separator and configured to recover energy for pre-heating the feedstock.
30. The system of claim 29, wherein: - the at least one heat exchanger downstream of the separator is configured to recover energy from the vapor; and
- the system further comprises a condensate tank downstream of the heat exchanger for collecting condensate from cooling the vapor.
31. The system of any one of claims 29 or 30, wherein the at least one heat exchanger downstream of the separator is configured to recover energy from the heated liquid.
32. The system of any one of claims 29 to 31, wherein: - the at least one heating stage comprises a plurality of heating stages; and - the energy recovered from one heating stage of the plurality of heating stages is used to pre-heat feedstock of another heating stage of the plurality of heating stages.
33. The system of claim 32, further comprising at least one vacuum system to control the temperature of the feedstock at each heating stage of the at least one heating stage.
34. The system of any one of claims 1 to 33, wherein the feedstock comprises brine.
35. The system of any one of claims 1 to 34, wherein the feedstock comprises non- soluble particles.
36. The system of any one of claims 1 to 35, wherein the vapor comprises steam.
37. A method of heating a feedstock in at least one heating stage, the method comprising, for each heating stage of the at least one heating stage: - pumping the feedstock into a lower portion of a vertically elongated body, the feedstock comprising a conductive liquid having an initial temperature and an initial pressure; - applying at least one alternating current to the feedstock within the vertically elongated body to heat the feedstock volumetrically to a saturation
temperature while the feedstock remains at the initial pressure, the feedstock being a fluid at the saturation temperature; - allowing the fluid to exit from an upper portion of the vertically elongated body; - after the fluid has exited the vertically elongated body, reducing a pressure of the fluid from the initial pressure to a lower pressure, the reduction in pressure causing vapor to flash off from the fluid; and - separating the vapor from heated liquid of the fluid, the heated liquid having a residual temperature that is higher than the initial temperature and lower than the saturation temperature.
38. The method of claim 37 comprises, for one or more heating stages of the at least one heating stage: - pumping the feedstock through a lower electrode positioned at a lower end of the vertically elongated body; - positioning an upper electrode at an upper end of the vertically elongated body to allow fluid to pass therethrough; and - exciting the lower electrode and the upper electrode to apply the at least one alternating current to the feedstock.
39. The method of claim 38 comprises, for the one or more heating stages of the at least one heating stage, positioning at least one intermediate electrode along the vertically elongated body and between the upper electrode and the lower electrode to allow at least a portion of the feedstock or the fluid to pass therethrough.
40. The method of claim 39 comprises, for the one or more heating stages of the at least one heating stage, applying the at least one alternating current to the at least one intermediate electrode to control a heating profile of the feedstock within the vertically elongated body.
41. The method of any one of claims 39 or 40 comprises grounding each of the upper electrode and the lower electrode.
42. The method of any one of claims 38 to 41 comprises providing a plurality of protrusions within each electrode to increase a surface area of the electrode that is in contact with the feedstock.
43. The method of any one of claims 38 to 42 comprises applying a DC current to the upper electrode to compensate for rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode.
44. The method of any one of claims 38 to 42 comprises discharging a capacitor to avoid rectification of the at least one alternating current across the upper electrode when the upper electrode is hotter than the lower electrode.
45. The method of any one of claims 38 to 44 comprises forming the lower electrode of a material having a higher resistivity than the upper electrode to minimize a temperature gradient between the upper electrode and the lower electrode.
46. The method of any one of claims 38 to 45 comprises resistively heating the lower electrode to minimize a temperature gradient between the upper electrode and the lower electrode.
47. The method of any one of claims 38 to 46, wherein, for the one or more heating stages of the at least one heating stage, the vertically elongated body comprises a length and a cross-sectional area adapted to enable a desired heating profile along the length of the vertically elongated body.
48. The method of any one of claims 38 to 46, wherein, for the one or more heating stages of the at least one heating stage, the vertically elongated body comprises a tube having a uniform diameter along a length of the tube.
49. The method of any one of claims 38 to 46, wherein, for the one or more heating stages of the at least one heating stage, the vertically elongated body comprises a tube having a varying diameter along a length of the tube.
50. The method of claim 49, comprises, for the one or more heating stages of the at least one heating stage, increasing a velocity of the fluid by configuring the upper portion to have a diameter that is smaller than a diameter of the lower portion.
51. The method of claim 50, wherein, for the one or more heating stages of the at least one heating stage, the expansion valve comprises an inlet formed by the upper electrode.
52. The method of any one of claims 50 or 51, wherein the expansion valve further comprises an outlet adjoined to the separator.
53. The method of any one of claims 50 to 52 comprises reducing electrical current outside of the vertically elongated body by returning the heated liquid to the feedstock to be pumped into the vertically elongated body.
54. The method of claim 49, comprises, for the one or more heating stages of the at least one heating stage, accelerating the heating of the feedstock by configuring the lower portion to have a diameter that is smaller than a diameter of the upper portion.
55. The method of any one of claims 50 to 54, wherein, for the one or more heating stages of the at least one heating stage: - the vertically elongated body is formed of an elastic material; and
- the method comprises operating a toroidal actuator coupled to a portion of the vertically elongated body to adjust a diameter of the portion of the vertically elongated body.
56. The method of any one of claims 38 to 55, comprises reducing heat loss by providing insulation around at least the vertically elongated body, the insulation being formed of an RF-transparent material.
57. The method of claim 37 comprises, for one or more heating stages of the at least one heating stage, exciting coaxial electrodes coupled to the vertically elongated body to apply the at least one alternating current to the feedstock.
58. The method of claim 37 comprises, for one or more heating stages of the at least one heating stage, exciting parallel plate electrodes coupled to the vertically elongated body to apply the at least one alternating current to the feedstock.
59. The method of any one of claims 38 to 58, wherein each electrode is formed of a material that is non-reactive to the alternating current.
60. The method of any one of claims 37 to 59, comprises, for one or more heating stages of the at least one heating stage, adjusting one or more of a frequency or a voltage of each alternating current of the at least one alternating current.
61. The method of claim 60 wherein adjusting one or more of a frequency or a voltage of each alternating current of the at least one alternating current is based on one or more of a desired heating profile along a length of the vertically elongated body, a cross-sectional area of the vertically elongated body, or a conductivity of the feedstock.
62. The method of any one of claims 37 to 61, wherein the frequency of the alternating current is greater than 100 Hz.
63. The method of any one of claims 37 to 62, comprises using one or more of a radio frequency (RF) generator, an alternating current (AC) generator, a microwave generator, or a millimeter wave generator to applying the at least one alternating current to the feedstock.
64. The method of any one of claims 37 to 63, comprises, for one or more heating stages of the at least one heating stage, recovering energy from the fluid to pre- heat the feedstock.
65. The method of claim 64, wherein: - recovering energy from the fluid comprises recovering energy from the vapor; and - the method comprises collecting condensate from cooling the vapor.
66. The method of any one of claims 64 or 65, wherein recovering energy from the fluid comprises recovering energy from the heated liquid.
67. The method of any one of claims 64 to 66, wherein: - the at least one heating stage comprises a plurality of heating stages; and - the method comprises using energy recovered from one heating stage of the plurality of heating stages to pre-heat feedstock of another heating stage of the plurality of heating stages.
68. The method of claim 67, comprising operating at least one vacuum system to control the temperature of the feedstock at each heating stage of the at least one heating stage.
69. The method of any one of claims 37 to 68, wherein the feedstock comprises brine.
70. The method of any one of claims 37 to 69, wherein the feedstock comprises non- soluble particles.
71. The method of any one of claims 37 to 70, wherein the vapor comprises steam.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202363579818P | 2023-08-31 | 2023-08-31 | |
| US63/579,818 | 2023-08-31 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2025043324A1 true WO2025043324A1 (en) | 2025-03-06 |
Family
ID=94817691
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/CA2024/051063 Pending WO2025043324A1 (en) | 2023-08-31 | 2024-08-15 | Systems and methods for heating a conductive feedstock |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2025043324A1 (en) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB863232A (en) * | 1957-12-11 | 1961-03-22 | Separator Ab | A method and an apparatus for continuous heat-treatment of liquids sensitive to heat |
| EP0032841A1 (en) * | 1980-01-21 | 1981-07-29 | The Electricity Council | Apparatus for heating electrically conductive flowable media |
| CA1168284A (en) * | 1980-03-24 | 1984-05-29 | Raymond H. Eaton-Williams | Multi-electrode boiler |
| US4767502A (en) * | 1986-05-26 | 1988-08-30 | Oy Santasalo-Sohlberg Ab | Steam generator in a multi-stage distilling apparatus |
| WO2012105864A1 (en) * | 2011-02-04 | 2012-08-09 | Vladimirskiy Vladimir Konstantinovich | Method and apparatus for heating current-conducting liquid, and heat-generating installation |
| CA2894137A1 (en) * | 2012-12-05 | 2014-06-12 | KIM, No Eul | Electrode boiler with electrodes unit |
-
2024
- 2024-08-15 WO PCT/CA2024/051063 patent/WO2025043324A1/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB863232A (en) * | 1957-12-11 | 1961-03-22 | Separator Ab | A method and an apparatus for continuous heat-treatment of liquids sensitive to heat |
| EP0032841A1 (en) * | 1980-01-21 | 1981-07-29 | The Electricity Council | Apparatus for heating electrically conductive flowable media |
| CA1168284A (en) * | 1980-03-24 | 1984-05-29 | Raymond H. Eaton-Williams | Multi-electrode boiler |
| US4767502A (en) * | 1986-05-26 | 1988-08-30 | Oy Santasalo-Sohlberg Ab | Steam generator in a multi-stage distilling apparatus |
| WO2012105864A1 (en) * | 2011-02-04 | 2012-08-09 | Vladimirskiy Vladimir Konstantinovich | Method and apparatus for heating current-conducting liquid, and heat-generating installation |
| CA2894137A1 (en) * | 2012-12-05 | 2014-06-12 | KIM, No Eul | Electrode boiler with electrodes unit |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| Zonouzi et al. | A review on effects of magnetic fields and electric fields on boiling heat transfer and CHF | |
| Yousefi et al. | Experimental investigation on the performance of CPU coolers: Effect of heat pipe inclination angle and the use of nanofluids | |
| US7159646B2 (en) | Electrohydrodynamically (EHD) enhanced heat transfer system and method with an encapsulated electrode | |
| Ma et al. | Freeze dehydration by microwave energy: Part I. Theoretical investigation | |
| CN106465530B (en) | Microwave plasma applicator with improved power uniformity | |
| KR102168481B1 (en) | Pressure controlled heat pipe temperature control plate | |
| CN102810447B (en) | The equipment for the treatment of substrate | |
| JP5947023B2 (en) | Temperature control apparatus, plasma processing apparatus, processing apparatus, and temperature control method | |
| CN106548917A (en) | Adjust the device and its temperature control method of device temperature in plasma etch chamber | |
| Liu et al. | Microwave-induced vapor-liquid mass transfer separation technology—full of breakthrough opportunities in electrified chemical processes | |
| US20140020405A1 (en) | Multistage Thermal Flow Device and Thermal Energy Transfer | |
| WO2025043324A1 (en) | Systems and methods for heating a conductive feedstock | |
| US5072780A (en) | Method and apparatus for augmentation of convection heat transfer in liquid | |
| Birnboim et al. | Simulation of microwave sintering of ceramic bodies with complex geometry | |
| WO2011028994A1 (en) | Enhanced flash chamber | |
| Deng et al. | Heat spreader based on room-temperature liquid metal | |
| US20080101022A1 (en) | Micro-fluidic cooling apparatus with phase change | |
| Garivalis et al. | Pool boiling performances comparison of FC-72 and Novec 649 in the presence of a DC electric field | |
| Uhm | Cherenkov radiation from a relativistic annular electron beam propagating through a dielectric loaded waveguide | |
| CN110455111B (en) | Active enhanced heat transfer device and active enhanced heat transfer method | |
| RU2340978C1 (en) | Electrode unit | |
| CN107795446A (en) | A kind of cooling device and cooling means of high-power electric propulsion device electrode | |
| Yabe et al. | Enhancement techniques in pool boiling | |
| JP2004533595A5 (en) | ||
| RU2791097C1 (en) | Liquid heater |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| 121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 24857538 Country of ref document: EP Kind code of ref document: A1 |