FIELD OF THE INVENTION

This application relates to apparatuses, systems, and methods for heating with electromagnetic waves, including microwaves.

BACKGROUND

Microwave energy can be used to process or heat a variety of materials in a number of industries, including the food and beverage industry and various chemical industries. For example, microwaves have been tested and applied in plasma processes (e.g., powder processing, chemical vapor infiltration, surface modification, etc.), chemical processing and synthesis, and waste remediation. Although significant effort has been made to expand the industrial use of microwave energy, little progress has been made.

The disadvantages commonly associated with the deployment of microwave energy include (i) the difficulties faced when designing an apparatus or process, (ii) the need for expensive equipment, (iii) an overall limited number of uses, (iv) the change in dielectric properties that can occur as temperature increases, or (v) a combination thereof.

There remains a need for apparatuses, systems, and methods for heating with microwaves that overcome one or more of these disadvantages, including apparatuses and methods for producing a heated fluid that may be employed, for example, in further processes as a source of heat.

BRIEF SUMMARY

Provided herein are apparatuses, systems, and methods that address one or more of the foregoing disadvantages, including methods for heating that do not rely completely upon the dielectric properties of a fluid. As a result, embodiments of the methods provided herein are not material specific, and are applicable to a broad range of fluids, as described herein, including organic fluids, inorganic fluids, aqueous fluids, etc., each of which may be polar or non-polar. The apparatuses and methods provided herein may include or rely on, respectively, a fixed bed system in which a flow of fluid contacts a susceptor material irradiated with electromagnetic waves, such as microwaves. The electromagnetic waves may be converted to heat by the susceptor material, thereby heating the fluid in a process that may be continuous. A fluid may be passed through the fixed bed system once or two or more times until a desired temperature of the fluid is reached. The apparatuses and systems herein also may permit a pressure to be applied to at least a part of the apparatuses or systems, such as a pressure greater than the critical pressure of a fluid, which may keep all or at least a portion of the fluid in the liquid phase and/or the supercritical phase.

In one aspect, apparatuses are provided herein. In some embodiments, the apparatuses include a tube; and an applicator, wherein (i) a first end of the tube is fixably mounted or spring mounted to the applicator, and (ii) at least a portion of the tube is arranged in the applicator. In some embodiments, the apparatuses include a tube; a susceptor material disposed in the tube; and an applicator, wherein (i) a first end of the tube is fixably mounted or spring mounted to the applicator, and (ii) at least a portion of the tube and at least a portion the susceptor material in the tube is arranged in the applicator. In some embodiments, a second end of the tube is fixably mounted or spring mounted to the applicator. The tube may include an inlet, an outlet, or an inlet and an outlet. The apparatuses also may include one or more microwave generators, wherein the one or more microwave generators are positioned to introduce a plurality of microwaves into an applicator to irradiate at least a portion of the susceptor material with the plurality of microwaves.

In some embodiments, the apparatuses include a container defining an internal volume configured to receive the susceptor particles; at least one retention device disposed in or adjacent to the internal volume and configured to retain the susceptor particles in the internal volume while allowing a fluid to flow out of the internal volume; and an electromagnetic wave emission structure configured to introduce electromagnetic waves into the internal volume for irradiation of the susceptor particles contained in the internal volume. The electromagnetic wave emission structure may include an electromagnetic wave-transparent section of the container through which electromagnetic waves can pass from outside the container into the internal volume. The container may include a tubular section formed of an electromagnetic wave-transparent material that makes up the electromagnetic wave-transparent section of the container. The apparatus may include an applicator for directing electromagnetic waves through the electromagnetic wave-transparent section and into the internal volume. In some embodiments, the electromagnetic wave emission structure is at least partially disposed in the container.

In another aspect, systems are provided herein. In some embodiments, the systems include a fluid source in which the fluid is disposed, wherein the fluid source is in fluid communication with the tube; and a pump configured to provide (i) the fluid to the tube and/or (ii) a pressure within the tube, wherein the pump is in fluid communication with the apparatus and the fluid source.

In yet another aspect, methods of heating a material, such as a fluid, are provided.

In some embodiments, the methods include contacting a fluid with a heated susceptor material, such as susceptor particles, to thereby heat the fluid at a rate of at least 100° C./min, at least 200° C./min, at least 300° C./min, at least 400° C./min, or at least 500° C./min. In some embodiments, the methods include providing an apparatus or system as described herein; disposing a fluid in the inlet of the tube at a flow rate; introducing a plurality of electromagnetic waves into the applicator to irradiate at least a portion of the susceptor material with the plurality of electromagnetic waves to generate heat while the fluid is in the tube to produce a heated fluid; and collecting the heated fluid at the outlet of the tube. In some embodiments, the methods also include (i) disposing at least a portion of the heated fluid in the inlet of the tube; (ii) introducing the plurality of electromagnetic waves into the applicator to irradiate at least a portion of the susceptor material with the plurality of electromagnetic waves to generate heat while the heated fluid is in the tube to produce a further heated fluid; and (iii) collecting the further heated fluid at the outlet of the tube.

In some embodiments, the methods include providing an apparatus or system as described herein; arranging a material adjacent the tube; introducing a plurality of electromagnetic waves into the applicator to irradiate at least a portion of the susceptor material with the plurality of electromagnetic waves to generate heat while the material is adjacent the tube to produce a heated material. The material may include a fluid, a solid, or a combination thereof. In some embodiments, the arranging of the material adjacent the tube includes contacting the tube with the material.

Additional aspects will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the aspects described herein. The advantages described herein may be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive.

