Method for producing a metal honeycomb-shaped catalyst support.

Abstract

We provide a technology that can support a sufficient amount of catalyst. [Solution] A method for manufacturing a metal honeycomb catalyst support includes: (a) a step of creating a plurality of individual metal fins constituting the catalyst support, wherein each individual fin has a shape in which corrugated fins are repeated at a constant fin pitch, and each individual fin is created such that the top of the corrugated fin is approximately semicircular in the cross-section of each individual fin; (b) a step of forming a metal honeycomb fin stack by stacking the plurality of individual fins; and (c) a step of brazing the plurality of individual fins of the fin stack, wherein the brazing is performed such that a fillet R of brazing material is formed between adjacent individual fins.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a metal honeycomb-shaped catalyst carrier.

Background Art

[0002] Patent Document 1 discloses a method for manufacturing a heat exchanger with honeycomb-shaped fins. In this method, a large number of metal foils are stacked on at least one of the upper and lower sides of flat or parallel metal tubes, and adhesive portions and non-adhesive portions are alternately formed between the metal foils and between the metal foils and the metal tubes.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when manufacturing a metal honeycomb-shaped catalyst carrier, there are problems that when a plurality of fins are stacked, the gaps between the fins become small and an insufficient amount of catalyst may not be supported. Also, when a plurality of fins are stacked and compressed, the fins may fit deeply into each other and the height of the fin laminate may become excessively small. Furthermore, there is also a problem that the fins may tilt and collapse when a plurality of fins are stacked and compressed. Therefore, a technique for solving at least some of these problems is desired.

Means for Solving the Problems

[0005] The present disclosure can be realized in the following forms.

[0006] (1) According to a first embodiment of the present disclosure, a method for manufacturing a metal honeycomb catalyst support is provided. The method includes (a) creating a plurality of individual metal fins constituting the catalyst support, wherein each individual fin has a shape in which corrugated fins are repeated at a constant fin pitch, and each individual fin is made such that the tops of the corrugated fins are substantially semicircular in the cross-section of each individual fin; (b) stacking the plurality of individual fins to form a metal honeycomb fin stack; and (c) brazing the plurality of individual fins of the fin stack, wherein the brazing is performed such that fillets R of brazing material are formed between adjacent individual fins. According to this method, since the top of the corrugated fin is approximately semicircular, a sufficient amount of catalyst can be supported in the corner R portion of the corrugated fin, thereby increasing the surface area of ​​the catalyst. Furthermore, since a wax fillet R is formed between adjacent fins, excessively small gaps do not occur between adjacent fins, allowing a sufficient amount of catalyst to be supported and increasing the surface area of ​​the catalyst. (2) In the above method, step (b) may include a step of stacking the plurality of individual fins and compressing them in the vertical direction, and determining the position of the plurality of individual fins by making the wavy fins of the stacked plurality of individual fins conform to each other. This method allows for the correct positioning of individual fins by making the wavy fins stacked vertically conform to each other. (3) In the above method, step (b) may include the step of inserting a metal plate between adjacent fins when stacking the plurality of individual fins. This method allows for the formation of a wax fillet radius between the fin and the flat plate. (4) A second embodiment of the present disclosure provides a method for manufacturing a metal honeycomb catalyst support. This method includes (a) creating a plurality of individual metal fins constituting the catalyst support, wherein each individual fin has a shape in which a bent fin having a bent cross-section is repeated at a constant fin pitch, and (b) stacking the plurality of individual fins to form a metal honeycomb fin stack. Each individual fin has a projection provided on the outside of the side surface of the bent fin, and when stacking the plurality of individual fins in step (b), the projection provided on each individual fin is configured to support an adjacent individual fin on the upper side. This method prevents the height of the fin stack from becoming excessively small even when multiple individual fins are compressed vertically. (5) A third embodiment of the present disclosure provides a method for manufacturing a metal honeycomb catalyst support. This method includes (a) creating a plurality of individual metal fins constituting the catalyst support, wherein each individual fin has a shape in which bent fins having a bent cross-section are repeated at a constant fin pitch, and (b) stacking the plurality of individual fins to form a metal honeycomb fin stack. Step (b) includes compressing the plurality of individual fins in the vertical direction with square pipes or U-shaped members provided on both sides of the plurality of individual fins. This method prevents the bent fins from collapsing even when multiple individual fins are compressed vertically. [Brief explanation of the drawing]

[0007] [Figure 1] An explanatory diagram showing a method for manufacturing a catalyst support in the first embodiment. [Figure 2] An explanatory diagram showing the compression process of multiple individual fins in the first embodiment. [Figure 3] An explanatory diagram showing the method for manufacturing the catalyst support in the second embodiment. [Figure 4]An explanatory diagram showing the method for manufacturing the catalyst support in the third embodiment. [Figure 5] An explanatory diagram showing the method for manufacturing the catalyst support in the fourth embodiment. [Figure 6] An explanatory diagram showing the compression process of multiple individual fins in the fifth embodiment. [Modes for carrying out the invention]

[0008] Figure 1 is an explanatory diagram showing a method for manufacturing a catalyst support in the first embodiment. At the top of Figure 1, multiple individual metal fins 110 that constitute a metal honeycomb-shaped catalyst support are shown. Each individual fin 110 has a corrugated shape in which wavy fins 111 are repeated at a constant fin pitch Pf.

[0009] In the cross-section of a single fin 110, the corrugated fin 111 has a shape in which two approximately semicircular peaks 112 are connected by a straight section 114. The corner radius (R) at the peaks 112 of the corrugated fin 111 is approximately equal to 1 / 4 of the fin pitch Pf. The corner radius (R) is the radius of the R-chamfer shape. It is preferable that the cross-section of the corrugated fin 111 has a shape that is 180 degrees rotationally symmetrical. The number of corrugated fins 111 included in a single fin 110 can be set to any number of 2 or more.

[0010] Figure 1 shows the X, Y, and Z directions relative to each other. The X and Y directions are horizontal, and the Z direction is upward. The X direction is the direction in which the corrugated fins 111 are repeatedly arranged, the Y direction is the direction in which the grooves of individual corrugated fins 111 extend, and the Z direction is the direction in which multiple individual fins 110 are stacked. Figure 1 shows a cross-section perpendicular to the Y direction. Individual fins 110 are also called "fin plates." Corrugated fins 111 are also called "bent fins."

[0011] As shown in the center of Figure 1, a metal honeycomb-shaped fin stack 100 is formed by stacking multiple individual fins 110. Then, as shown in the lower part of Figure 1, adjacent individual fins 110 are brazed together. The amount of brazing material 120 is adjusted so that a fillet R (fillet radius) is formed between adjacent individual fins 110. The fillet R is an R-shaped chamfer formed at the corner of the brazing material 120. In Figure 1, the fillet R is indicated by the lowercase letter "r". After this, a catalyst support can be manufactured by supporting the catalyst on the fin stack 100. A common method for supporting the catalyst on the fin stack 100 is to apply a slurry-like catalyst coating material. Because this coating material has high viscosity, it does not penetrate into deep, minute gaps, which may reduce the surface area and amount of catalyst coated. In the first embodiment, since a wax fillet R is formed between adjacent fins 110, an excessively small gap is not created between adjacent fins 110, a sufficient amount of catalyst can be supported, and the surface area of ​​the catalyst can be increased.

[0012] Figure 2 is an explanatory diagram showing the compression process of multiple individual fins 110 in the first embodiment. The top of Figure 2 shows how the upper and lower individual fins 110 are misaligned before they are stacked and compressed.

[0013] The central and bottom parts of Figure 2 show the compressed state. Flat plates 610 and 620 are placed above and below the multiple individual fins 110. When the multiple individual fins 110 are compressed vertically using the flat plates 610 and 620, the tops 112 of the corrugated fins 111 become approximately semicircular, allowing the upper and lower corrugated fins 111 to conform to each other. As a result, the lower individual fins 110 move along direction Df, and their respective positions are determined in such a way that the misalignment between the multiple individual fins 110 is eliminated.

[0014] As described above, in the first embodiment, since the top portion 112 of the corrugated fin 111 is substantially semi-circular, a sufficient amount of catalyst can be supported on the corner R portion of the corrugated fin 111, and the surface area of the catalyst can be increased. Also, since a fillet R of the brazing material is formed between adjacent fin units 110, an excessively small gap does not occur between adjacent fin units 110, a sufficient amount of catalyst can be supported, and the surface area of the catalyst can be increased.

[0015] FIG. 3 is an explanatory diagram showing a method for manufacturing a catalyst carrier in the second embodiment. The main difference from the first embodiment shown in FIG. 1 is the shape of the fin unit 210. That is, the corrugated fin 211 of the fin unit 210 in the second embodiment has a shape in which a plurality of substantially semi-circular tops 212 are connected to each other and does not have the straight portion 114 in the first embodiment. However, the corrugated fin 211 has the same corrugated plate shape that is repeated at a constant fin pitch Pf as in the first embodiment. Also, the corner R (rounded corner) at the top 212 of the corrugated fin 211 is substantially equal to 1 / 4 of the fin pitch Pf, which is also the same as in the first embodiment.

[0016] As shown in the center of FIG. 3, in the second embodiment, when stacking a plurality of fin units 210, a flat metal plate 230 is disposed between adjacent fin units 210 to form a metal honeycomb-like fin laminate 200. Then, as shown in the lower part of FIG. 3, the fin unit 210 and the flat plate 230 are brazed to form a fillet R of the brazing material 220 between the fin unit 210 and the flat plate 230. The fillet R of the brazing material 220 in the second embodiment can also be considered to be formed between adjacent fin units 210. The second embodiment also has substantially the same effect as the first embodiment described above.

[0017] FIG. 4 is an explanatory diagram showing a method for manufacturing a catalyst carrier in the third embodiment. The main difference from the first embodiment shown in FIG. 1 is that the fin unit 310 is provided with protrusions 315. That is, the fin unit 310 of the third embodiment has protrusions 315 provided on the outer side of the side surface of the corrugated fin 311. Further, the fin unit 310 has substantially the same shape as the fin unit 110 of the first embodiment except for the protrusions 315.

[0018] A plurality of protrusions 315 are provided along the Y direction, which is the direction in which the groove portion of the corrugated fin 311 extends, on the side surface of the corrugated fin 311. In the example of FIG. 4, the protrusions 315 have a plate-like shape that protrudes obliquely upward on the outer side of the side surface of the corrugated fin 311. Instead of this, louver-like protrusions extending in the vertical direction (Z direction) may be provided on the side surface of the corrugated fin 311.

[0019] The protrusions 315 can be formed, for example, by processing a flat metal plate before processing the fin unit 310 into a corrugated plate shape. Specifically, after forming linear or U-shaped slits in the flat metal plate, the protrusions 315 can be formed by pushing out the portions around the slits to the outside. Alternatively, the protrusions 315 may be formed by embossing without providing slits.

[0020] In the example of FIG. 4, the protrusions 315 are provided on the outer side of the right side surface of each corrugated fin 311, but the protrusions 315 may also be provided on the outer side of the left side surface of the corrugated fin 311.

[0021] As shown in the center of Figure 4, in the third embodiment, when multiple individual fins 310 are stacked, the fin stack 300 is formed with the upper individual fins 310 supported by the projections 315 of the lower individual fins 310. Therefore, even if the multiple individual fins 310 are compressed in the vertical direction, it is possible to prevent the height of the fin stack 300 from becoming excessively small. Subsequently, as shown in the lower part of Figure 4, adjacent individual fins 310 are brazed together to form a fillet R of brazing 320. Furthermore, a catalyst support can be manufactured by supporting the catalyst on the fin stack 300.

[0022] The third embodiment also provides substantially the same effects as the first embodiment described above. Furthermore, in the third embodiment, since a projection 315 is provided on the outside of the side surface of the corrugated fin 311, it is possible to prevent the height of the fin stack 300 from becoming excessively small even when multiple individual fins 310 are compressed in the vertical direction.

[0023] Figure 5 is an explanatory diagram showing a method for manufacturing a catalyst support in the fourth embodiment. The main difference from the third embodiment shown in Figure 4 is only the shape of the individual fins 410. That is, the individual fins 410 of the fourth embodiment have a shape in which rectangular fins 411 having a substantially rectangular wave-shaped cross-section are repeated at a constant fin pitch Pf. On the outer side of the side surface of the rectangular fins 411, protrusions 415 similar to the protrusions 315 of the third embodiment are provided. Preferably, the cross-sectional shape of the rectangular fins 411, excluding the protrusions 415, has 180-degree rotational symmetry. Furthermore, it is preferable that the corners of the rectangular shape of the rectangular fins 411 are chamfered.

[0024] The lamination process in the fourth embodiment is substantially the same as that in the third embodiment. That is, when multiple individual fins 410 are laminated, the fin laminate 400 is formed with the upper individual fins 410 being supported by the protrusions 415 of the lower individual fins 410.

[0025] It is preferable that the upper end of the projection 415 of the rectangular fin 411 is lower than the upper end of the rectangular fin 411. When two individual fins 410 are stacked, it is preferable that each projection 415 contacts the bottom of the rectangular fin 411 above it. Furthermore, with the projection 415 in contact with the bottom of the rectangular fin 411 above it, it is preferable that a part of the surface of the rectangular fin 411 having the projection 415 and a part of the back surface of the rectangular fin 411 above it contact each other. In the example in the center of Figure 5, the corner portion of the surface of the lower rectangular fin 411 and the corner portion of the back surface of the upper rectangular fin 411 are in contact with each other. In this way, the lower individual fin 410 can firmly support the upper individual fin 410.

[0026] Subsequently, as shown in the lower part of Figure 5, adjacent individual fins 410 are brazed together to form a fillet R of brazing material 420. Furthermore, a catalyst support can be manufactured by supporting the catalyst on the fin stack 400.

[0027] Furthermore, the corrugated fin 311 in the third embodiment and the rectangular fin 411 in the fourth embodiment are similar in that they are fins having a bent cross-section. In this disclosure, fins having a bent cross-section, such as the corrugated fin 311 and the rectangular fin 411, are also referred to as "bent fins."

[0028] Figure 6 is an explanatory diagram showing the compression process of multiple individual fins 510 in the fifth embodiment. The individual fins 510 in the fifth embodiment have a shape in which rectangular fins 511 having a substantially rectangular wave-shaped cross-section are repeated at a constant fin pitch Pf. In the fifth embodiment, unlike the fourth embodiment described above, no protrusions are provided on the outside of the side surface of the rectangular fins 511, but protrusions similar to those in the fourth embodiment may be provided.

[0029] When stacking and compressing multiple individual fins 510, flat plates 610 and 620 are placed above and below the individual fins 510. In addition, a square pipe 630 is placed on the left side of the individual fins 510, and a U-shaped member 640 is placed on the right side. For the U-shaped member 640, for example, a metal U-shaped angle can be used.

[0030] Using a metal square pipe 630 is preferable because, during brazing, the fin stack 500 can be cooled by flowing a coolant through the square pipe 630. Even when using a metal U-shaped member 640, if the U-shaped member 640 has a sufficiently large heat capacity, the fin stack 500 can be cooled by the U-shaped member 640 itself. Alternatively, the square pipe 630 may be placed on both sides of multiple individual fins 510, or the U-shaped member 640 may be placed on both sides of multiple individual fins 510.

[0031] In the fifth embodiment, multiple individual fins 510 are compressed vertically with square pipes 630 or U-shaped members 640 provided on both sides of each fin. As a result, even when multiple individual fins 510 are compressed vertically, it is possible to prevent the rectangular fins 511 from tilting and collapsing. In addition, the height Hd of the compressed fin stack 500 can be adjusted to the design height. Subsequently, adjacent individual fins 510 are brazed together, and a catalyst can be supported on the fin stack 500 to produce a catalyst carrier.

[0032] Furthermore, the compression process using the square pipe 630 or the U-shaped member 640 can also be applied to the first to fourth embodiments described above. That is, the compression process using the square pipe 630 or the U-shaped member 640 can be applied when a fin laminate is formed by stacking multiple individual fins having a bent cross-section.

[0033] Other forms: This disclosure is not limited to the embodiments described above, and can be implemented in various forms without departing from its spirit. For example, this disclosure can also be implemented in the following forms (aspects). The technical features in the embodiments described above that correspond to the technical features in each of the forms described below can be replaced or combined as appropriate in order to solve some or all of the problems of this disclosure, or to achieve some or all of the effects of this disclosure. Furthermore, if such technical features are not described as essential in this specification, they can be deleted as appropriate.

[0034] This disclosure can also be implemented in various forms other than a method for manufacturing a metal honeycomb catalyst support. For example, it can be implemented in the form of a fin stack, a method for manufacturing the same, or a metal honeycomb catalyst support. [Explanation of Symbols]

[0035] 100...Fin stack, 110...Single fin, 111...Wavy fin (bent fin), 112...Top, 114...Straight section, 120...Wax, 200...Fin stack, 210...Single fin, 211...Wavy fin (bent fin), 212...Top, 220...Wax, 230...Flat plate, 300...Fin stack, 310...Single fin, 311...Wavy fin (bent fin), 315...Protrusion, 320...Wax, 400...Fin stack, 410...Single fin, 411...Rectangular fin (bent fin), 415...Protrusion, 420...Wax, 500...Fin stack, 510...Single fin, 511...Rectangular fin (bent fin), 610, 620...Flat plate, 630...Square pipe, 640...U-shaped member

Claims

1. A method for producing a metal honeycomb-shaped catalyst support, (a) A step of creating a plurality of individual metal fins that constitute the catalyst support, wherein each individual fin has a shape in which corrugated fins are repeated at a constant fin pitch, and each individual fin is created such that the top of the corrugated fin in the cross-section of each individual fin is substantially semicircular, (b) A step of forming a metal honeycomb-shaped fin stack by stacking the plurality of individual fins, (c) A step of brazing the plurality of individual fins of the fin stack, the step of performing the brazing such that a fillet R of brazing material is formed between adjacent individual fins, A method that includes this.

2. The method according to claim 1, The method comprises step (b) stacking the plurality of individual fins and compressing them in the vertical direction, and determining the position of the plurality of individual fins by making the wavy fins of the stacked plurality of individual fins conform to each other.

3. The method according to claim 1, The method comprising step (b) of inserting a metal plate between adjacent fins when stacking the plurality of individual fins.

4. A method for producing a metal honeycomb-shaped catalyst support, (a) A step of creating a plurality of individual metal fins that constitute the catalyst support, wherein each individual fin is created such that each individual fin has a shape in which a bent fin having a bent cross-section is repeated at a constant fin pitch, (b) A step of forming a metal honeycomb-shaped fin stack by stacking the plurality of individual fins, Includes, A method wherein each individual fin has a projection provided on the outer side of the side surface of the bent fin, and when stacking the plurality of individual fins in step (b), the projection provided on each individual fin is configured to support the individual fin adjacent to it on the upper side.

5. A method for producing a metal honeycomb-shaped catalyst support, (a) A step of creating a plurality of individual metal fins that constitute the catalyst support, wherein each individual fin is created such that each individual fin has a shape in which a bent fin having a bent cross-section is repeated at a constant fin pitch, (b) A step of forming a metal honeycomb-shaped fin stack by stacking the plurality of individual fins, Includes, The method includes step (b) of compressing the plurality of fins in the vertical direction while square pipes or U-shaped members are provided on both sides of the plurality of fins.

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