Bolted Catalyst Module Frame With Elastic Sealing
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Solution Overview
Problem
Conventional catalyst modules in stationary combustion systems face challenges with high manufacturing costs and leakage due to complex welding processes and thermal expansion issues, which affect flow efficiency and sealing.
Innovation Solution
A catalyst module design featuring a bolted stack frame with plug-in element boxes and an elastic sealing element, eliminating the need for welding and allowing for flexible assembly and reduced material usage, ensuring secure sealing and improved flow properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to assemble the stack frame and element boxes, then mechanical strength and structural stability are improved, but manufacturing complexity and cost increase, and thermal expansion issues cause leakage
Solution Approach 1:
The stack frame and element boxes are divided into modular components that can be assembled separately and then connected. This segmentation allows for simplified manufacturing of individual parts while maintaining overall structural integrity through the modular assembly approach.
Solution Approach 2:
The connection system incorporates dynamic elements that can accommodate thermal expansion and contraction of the metal components. The sealing mechanism is designed to remain effective despite dimensional changes in the welded or bolted structure during temperature cycles.
2Stability of the object's composition
If welding is used to assemble the stack frame and element boxes, then structural stability is improved, but manufacturing cost and time increase due to complex welding processes
Solution Approach 1:
The element boxes are pre-assembled with their sealing surfaces and gaskets before being installed in the stack frame. This preliminary preparation ensures proper alignment and sealing without requiring complex on-site welding or assembly operations, reducing both cost and time.
Solution Approach 2:
A sealing element or gasket acts as an intermediary between the stack frame and element boxes, providing the necessary seal without requiring direct welding between these components. This intermediary approach simplifies the connection process while maintaining structural stability.
3Reliability
If rigid sealing elements are used between metal components, then sealing is improved under stable conditions, but thermal expansion causes detachment and leakage
Solution Approach 1:
The sealing element is made from a flexible material such as rubber or elastomer that can deform to accommodate thermal expansion and contraction of the metal components. This flexibility allows the seal to maintain contact and prevent leakage despite dimensional changes in the surrounding structure.
Solution Approach 2:
The sealing system is designed to change its physical parameters (such as compression force or contact pressure) in response to thermal expansion. The flexible material naturally adjusts its deformation characteristics with temperature, maintaining effective sealing across a range of operating conditions.
4Strength
If element boxes have folded edges oriented perpendicular to flow direction, then structural reinforcement is improved, but flow resistance increases
Solution Approach 1:
The reinforcement structure is moved from the flow-facing surface to the edges or corners of the element boxes. By placing structural strengthening elements in a different spatial dimension (at the boundaries rather than on the flow surface), the design maintains structural integrity while minimizing interference with fluid flow.
Solution Approach 2:
Reinforcement is applied locally at specific critical points such as corners or edges where structural strength is most needed, rather than across the entire surface. This localized reinforcement approach provides necessary strength while leaving the flow-facing surfaces smooth and minimally obstructive.
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
This design simplifies production, reduces manufacturing costs, and enhances cleaning efficiency by minimizing leakage and back-pressure, while allowing the use of weaker catalysts due to improved insulation and flow guidance.
Implementation Method 1
an elastic sealing element which, in a compressed state, is arranged between at least one side frame part and at least one mounting unit
Implementation Method 2
because of different thermal coefficients of expansion, this strip-shaped sealing element may become detached in operation
Data Source
Figure 1~2
Figure 3~5
Figure 6~9
AI summary
The catalyst module (2) is designed for use in an emission control system of an industrial scale combustion system. It comprises a stack frame (4), in which several mounting units, especially element boxes (6) are inserted. Each of these is provided with several catalysts (10). In order to make a simple installation possible and, at the same time, a reliable sealing, the stack frame (4) is assembled from side frame parts (20, 22, 24), which are connected and especially bolted to one another via mechanical connecting elements, a sealing element (30), which is inserted during the installation before the connection of the at least one side frame part (20, 24) and pressed against at least one element box (6) with the help of the connecting element, being present at least at a side frame part (20, 24).