Catalyst-Coated Particulate Filter for Heavy Fuel Oil Exhaust
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Solution Overview
Problem
Existing particulate filter systems designed for diesel engines are inadequate for maritime engines fueled with heavy fuel oil, as they cannot effectively handle high sulfur and ash content, leading to increased pressure drops and the need for frequent manual regeneration.
Innovation Solution
A method and system for continuous passive regeneration of particulate filters using soot combustion and hydrocarbon oxidation catalysts, combined with periodic ash removal through reverse pulse injection of air, allowing for continuous engine operation without shutting off the filtration units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If particulate filters are used to capture soot and ash from heavy fuel oil exhaust, then particle removal efficiency is improved, but pressure drop increases and filters require frequent regeneration
Solution Approach 1:
The patent applies preliminary action by coating the particulate filter with catalyst material before operation. This catalyst layer is pre-applied to facilitate soot combustion at lower temperatures, enabling the filter to maintain lower pressure drop while effectively removing particles from heavy fuel oil exhaust
Solution Approach 2:
The patent changes the chemical parameters of the filter by impregnating it with catalyst materials (such as precious metals or metal oxides). This modification allows the filter to operate at lower temperatures and maintain reduced pressure drop while achieving effective particle removal through catalyzed soot combustion
2Manufacturing precision
If filters are regenerated by manual processes, then ash removal is achieved, but system downtime increases and operation continuity is reduced
Solution Approach 1:
The patent implements self-service by enabling the filter to perform its own regeneration through catalyzed soot combustion. The catalyst-coated filter automatically combusts accumulated soot at lower temperatures, reducing the need for manual intervention and maintaining continuous system operation
Solution Approach 2:
The patent ensures continuity of useful action by designing a system where the catalyst facilitates ongoing soot combustion during normal operation. This continuous passive regeneration maintains filter performance without requiring system shutdown, thereby preserving productivity
3Device complexity
If conventional filters are used for diesel exhaust, then system complexity is kept low, but they cannot handle high sulfur and ash content from heavy fuel oil
Solution Approach 1:
The patent applies local quality by modifying only the surface properties of the filter through catalyst coating, rather than changing the entire filter structure. This localized modification enables the filter to handle heavy fuel oil contaminants while maintaining the overall simplicity of the filtration system
Solution Approach 2:
The patent uses composite materials by combining the base filter material with catalyst materials (such as precious metals, metal oxides, or mixed oxides). This composite structure provides both the mechanical filtration function and the catalytic activity needed to handle high sulfur and ash content from heavy fuel oil
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 approach maintains low pressure drop across filters, facilitates ash removal, and reduces the need for additional additives, enabling continuous operation and compact filtration assemblies, even in high-particle-load environments like cement production processes.
Implementation Method 1
continuously burning the captured soot and adhered hydrocarbons off the at least one particulate filter by contact with a catalyst being arranged on the filter
Implementation Method 2
continuously burning the captured soot and adhered hydrocarbons off the at least one particulate filter
Implementation Method 3
subsequently pulse injecting air into the outlet of at least one of the filtration units in reverse to the previous flow of the exhaust gas and blowing the particles off the at least one particulate filter
Data Source
AI summary
Method and system for removal of particles such as soot, ash and heavy metals, and optionally additionally NOX and SOX being present in exhaust gas from an engine or process equipment.