Catalysed Filter Hollow Section Catalyst Placement

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Solution Overview

Problem

Existing catalytic filter systems for particulate-containing exhaust gases face challenges such as catalyst deactivation, increased backpressure, and reduced mechanical strength due to the integration of catalysts within the filter walls, limiting design flexibility and efficiency.

Innovation Solution

A catalysed filter system with a substrate material supporting a catalyst component inserted within the hollow section of an elongate filter element, allowing for flexible catalyst placement and reduced backpressure, enabling efficient filtration and retrofitting of existing filters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If catalyst is integrated within the filter walls, then catalytic treatment function is achieved, but mechanical strength of the filter is reduced

Engineering Contradiction:

Improvecatalytic treatment functionVSAvoidmechanical strength of filter

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The filter system is divided into two separate functional components: a filter element for particulate removal and a catalyst component for gaseous contaminant treatment. The catalyst component is disposed within the hollow section of the filter element, creating a segmented structure where each component maintains its structural integrity while working together as an integrated system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The catalyst component is nested within the hollow section of the filter element, creating a nested structure where the catalyst holder is positioned inside the filter's internal cavity. This nesting arrangement allows both components to occupy the same spatial envelope without compromising the mechanical strength of either component.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Adaptability or versatility

If catalyst is integrated within the filter walls, then catalytic treatment function is achieved, but backpressure increases

Engineering Contradiction:

Improvecatalytic treatment functionVSAvoidbackpressure

Core Design Contradiction:

Adaptability or versatilityVSStress or pressure

Solution Approach 1:

By separating the filtration and catalysis functions into distinct components, the flow paths are optimized independently. The filter element handles particulate removal with its porous walls, while the catalyst component in the hollow section handles gaseous contaminant treatment, allowing each to operate at optimal pressure differentials without excessive backpressure buildup.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hollow section acts as an intermediary chamber between the filter's external environment and the catalyst component. This intermediate space allows for controlled gas flow distribution across the catalyst, reducing flow resistance and minimizing backpressure while ensuring adequate contact between exhaust gas and catalyst surface.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If catalyst is integrated within the filter walls, then catalytic treatment function is achieved, but design flexibility is reduced

Engineering Contradiction:

Improvecatalytic treatment functionVSAvoiddesign flexibility

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The segmented design with separate filter and catalyst components enables independent selection and optimization of each component's properties. Different catalyst materials, geometries, and activities can be chosen based on specific application requirements without redesigning the entire filter structure, significantly enhancing design flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular catalyst component can be dynamically adjusted, replaced, or configured based on varying operational requirements. The hollow section accommodates different catalyst holder designs, catalyst loadings, and catalyst types, allowing the system to adapt to changing emission profiles and performance requirements.

Inventive Principle:

Principle #15Dynamics

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 configuration enhances filtration efficiency, reduces backpressure, and allows for multiple catalyst functions in a single filter, improving operational efficiency and extending catalyst lifespan.

Implementation Method 1

an elongate filter element comprising porous walls which define a hollow section

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Implementation Method 2

a substrate material supporting a catalyst component disposed within the hollow section

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS11833471B2Catalysed filter system for treating particulate-containing exhaust gas from stationary emission sources

Publication Date: 2023.12.05 JOHNSON MATTHEY PLC

AI summary

A catalysed filter system for treating particulate-containing exhaust gas from a stationary emission source comprises an elongate filter element comprising porous walls which define a hollow section and a substrate material supporting a catalyst component disposed within the hollow section, the arrangement being such that gas entering the hollow section of the elongate filter element from across the porous walls thereof must contact the substrate material supporting the catalyst component before exiting the hollow section of the elongate filter element.