Catalyst Carrier Module Segmentation Eliminates Brazing
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Solution Overview
Problem
Current catalyst carrier modules for large-capacity catalyst reactors face challenges in manufacturing complexity, cost, and productivity due to the need for brazing or welding of wave and flat plates, which complicates assembly and increases costs, especially for large-scale applications like ships and power plants.
Innovation Solution
A catalyst carrier module design featuring a rectangular tube can with alternately laminated wave and flat plates coated with catalysts, where fixing units with extension portions and wedge members prevent detachment, allowing for assembly without forming an integrated wave/flat plate assembly, thus simplifying the manufacturing process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wave plates and flat plates are brazed or welded to form an integrated assembly, then structural integrity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The catalyst carrier is divided into modular units consisting of separate wave plates and flat plates that are not permanently joined. These modular units can be independently manufactured and then assembled by simple stacking, eliminating the need for complex brazing or welding processes while maintaining structural integrity through the alternating layered configuration
Solution Approach 2:
Multiple wave plates and flat plates are combined through simple stacking and alternating arrangement to form the complete catalyst carrier structure. The modular units are merged by placement rather than permanent joining, simplifying manufacturing while achieving the required structural strength through the interlocked alternating pattern
2Strength
If wave plates and flat plates are brazed or welded to form an integrated assembly, then structural integrity is improved, but productivity decreases
Solution Approach 1:
The catalyst carrier is segmented into separate wave plate and flat plate components that can be manufactured independently and simultaneously. This segmentation enables parallel production processes and eliminates time-consuming joining operations, significantly improving manufacturing productivity while maintaining structural integrity through the alternating layered assembly
Solution Approach 2:
The wave plates and flat plates are prepared in advance as separate pre-fabricated components with catalyst coatings applied beforehand. This preliminary preparation allows independent optimization of each component's manufacturing process and enables rapid final assembly without requiring complex joining operations during production
3Strength
If an integrated wave plate/flat plate assembly is fabricated by brazing, welding, soldering, or diffusion bonding, then structural integrity is improved, but manufacturing cost increases
Solution Approach 1:
The catalyst carrier structure is segmented into separate wave plates and flat plates that are manufactured independently and assembled by simple stacking. This eliminates the need for expensive brazing, welding, soldering, or diffusion bonding processes while maintaining structural integrity through the alternating layered configuration and mechanical interlocking
Solution Approach 2:
The design uses simple, inexpensive wave plates and flat plates that can be manufactured using low-cost processes. Rather than investing in complex joining technologies, the system achieves structural integrity through the alternating arrangement of simple components, significantly reducing manufacturing costs
Data Source
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AI summary
Provided is a catalyst carrier module for a large-capacity catalyst reactor, which can be assembled in a large-capacity structure by laminating a flat plate and a wave plate to then be fixed in a can without brazing the flat plate and the wave plate constituting a cell forming body, for use in a catalytic reactor requiring a large-capacity exhaust gas treatment, to thereby manufacture the catalyst carrier module with a simple process and at low cost. The catalyst carrier module (or block) comprising: a can of a rectangular tube shape having an inlet and an outlet; at least one cell forming body in which a plurality of hollow cells are formed by alternately laminating a wave plate and a flat plate which are coated with a catalyst on a surface thereof and inserted into the can; and a fixing unit installed at the inlet and the outlet of the can to prevent the at least one cell forming body from detaching from the can.