Abstract
Hard-to-abate industrial processes, such as petrochemicals and cement production, have long been considered technically challenging to decarbonize. In response to the urgent demand to eliminate industrial CO2 emissions, a new class of energy-imparting turbomachines has been developed. These devices aim to convert mechanical into internal energy instead of pressurizing the gas, which enables high-temperature gas heating (up to 1700 C) for a variety of applications. This article is organized into three parts. First, this article aims to demonstrate the capabilities of the novel, high-capacity, customizable, repeating-stage axial turbo-heater architecture for a hydrocarbon cracking example application. The study presents the new design requirements and working principles of this energy-imparting concept. The radically different objectives compared to a compressor enable ultra-high loading stage designs by avoiding the stability and efficiency constraints imposed on compressors. Within this new design space, the turbo-heater is able to achieve a loading coefficient ψ ≥ 4.0. Second, detailed numerical simulations of a multistage axial turbo-reactor with various vaneless space lengths are conducted. This work conclusively demonstrates the robustness and flexibility of the aerodynamic design despite employing a uniform blade design. It is emphasized that the concept is tolerant to unsteady interstage turbulent disturbances, enabling nominal work input conditions to be achieved even for the most compact arrangements. Finally, having confirmed that the aerothermal restrictions on the vaneless space length can be removed, the designer is free to tailor the design to optimize the chemical reaction by (1) tailoring the residence time distribution to improve the yield and coking rate, (2) homogenizing reaction progress by mixing-out concentration gradients, and (3) adjusting the rotational speed to account for variations in the reaction dynamics for different feedstocks.
