Alumina Sol Binder Ceramic Insulation for Steam Reforming
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Solution Overview
Problem
Existing self-supporting moulded insulation bodies made of SiO2 and Al2O3 fibers for steam reforming processes have inadequate service life due to binder expulsion at high temperatures, leading to instability and disintegration.
Innovation Solution
Using an Al2O3 sol as a binder and producing moulded insulation bodies under vacuum conditions, with circular arc or cylindrical profiles for easier installation and improved thermal protection, addresses the service life issue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional binders (SiO2-containing and/or organic binder) are used in moulded insulation bodies, then the insulation bodies can be manufactured with existing processes, but the service life is inadequate due to binder expulsion at high temperatures
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by using Al2O3 sol instead of conventional SiO2-containing or organic binders. This parameter change allows the binder to withstand high temperatures and steam conditions without expulsion, directly resolving the service life issue while maintaining manufacturability
Solution Approach 2:
The patent creates a composite binder system combining Al2O3 sol with ceramic fibers (SiO2 and Al2O3). This composite material approach ensures the binder maintains its binding function while resisting thermal degradation and steam attack, thereby extending service life without compromising manufacturing processes
2Ease of operation
If tapes or mats are used as insulation material, then the material can be installed, but fitting and disassembly is complex and inconvenient
Solution Approach 1:
The patent segments the insulation system into modular moulded bodies with specific geometric shapes (circular arc profiles, cylindrical shapes) that can be individually installed in cracking tubes. This segmentation transforms the complex fitting process of tapes and mats into simpler, standardized module installation, improving ease of operation while reducing overall system complexity
Solution Approach 2:
The patent employs curved geometries (circular arc profiles, cylindrical shapes) for the moulded insulation bodies that match the curvature of cracking tubes. This design allows the insulation bodies to be easily installed and removed without complex fitting procedures, directly addressing the convenience issue while maintaining structural integrity
3Object-affected harmful factors
If internal insulation is installed in cracking tubes, then thermal protection is provided, but the insulation material must resist high temperatures and steam without disintegrating
Solution Approach 1:
The patent modifies the chemical and thermal parameters of the binder by using Al2O3 sol, which has superior high-temperature stability compared to conventional binders. This parameter change enables the insulation body to maintain its structural integrity and binding function under the harsh conditions of high temperature and steam exposure in steam reforming processes
Solution Approach 2:
The patent develops a composite ceramic material system combining Al2O3 sol binder with SiO2 and Al2O3 fibers. This composite structure provides both the thermal protection function and the chemical/thermal stability required to resist disintegration under process conditions, simultaneously addressing both requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution extends the service life of insulation bodies and ensures better thermal protection and ease of maintenance, reducing heat losses and metal dusting corrosion in steam reforming processes.
Implementation Method 1
using an Al2O3 sol as a binder
Implementation Method 2
kilning at temperatures between 815° C. and 1260° C.
Implementation Method 3
producing moulded insulation bodies under vacuum conditions
Implementation Method 4
Volatile components are then removed by applying a vacuum
Implementation Method 5
to prevent heat losses and burns to operators
Data Source
AI summary
Moulded insulation bodies, processes for the production thereof and use thereof consisting essentially of ceramic material comprising SiO2 fibers and Al2O3 fibers which has been produced using Al2O3 sol as a binder and kilned at a temperature of above 800° C. for insulation of the ends of cracking tubes of a tubular reactor for performing a steam reforming process for generating synthesis gas which project out of the reactor heating space.