Catalyst Module Duct Configuration for Exhaust Pressure Drop Reduction
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Solution Overview
Problem
Existing catalytic reactors experience inefficiencies due to pressure drop in exhaust gas streams, leading to parasitic power losses and reduced performance in nitrogen oxide reduction.
Innovation Solution
The design of catalyst modules and catalytic reactors with increased effective cross-sectional area, featuring a configuration of catalyst bodies and ducts that facilitate fluid stream flow, reducing pressure drop without compromising catalytic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exhaust gas streams flow through modularized sections of a catalytic reactor, then nitrogen oxides are removed through catalytic reduction, but pressure drop increases causing inefficiencies and parasitic power losses
Solution Approach 1:
The catalytic reactor is divided into multiple modularized sections with catalyst bodies arranged in series. Each module contains catalyst bodies that can be independently configured, allowing optimization of flow distribution while maintaining catalytic function. The segmentation enables parallel flow paths that reduce overall pressure drop.
Solution Approach 2:
The patent introduces ducts that extend in the longitudinal direction between catalyst bodies, creating additional flow dimensions. Exhaust gas can flow through multiple pathways (through catalyst bodies and through ducts), effectively increasing the cross-sectional area available for flow and reducing pressure drop in the longitudinal dimension.
2Reliability
If catalyst bodies are arranged in modularized sections, then catalytic reduction of nitrogen oxides is achieved, but pressure drop results from structures and frictional forces
Solution Approach 1:
Ducts are introduced as intermediary structures between catalyst bodies. These ducts provide low-resistance flow paths that mediate between the catalyst bodies, allowing exhaust gas to transition between modules with minimal pressure loss. The ducts act as flow conduits that reduce frictional forces compared to direct catalyst body-to-catalyst body interfaces.
Solution Approach 2:
The effective cross-sectional area for gas flow is increased by adding ducts, which changes the flow parameters. This parameter change reduces velocity through the catalyst bodies and lowers pressure drop according to the Darcy-Weisbach equation, while maintaining sufficient contact time for catalytic reduction.
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 lowers overall pressure drop through the catalyst modules and reactors, maintaining effective catalytic performance in nitrogen oxide reduction and other fluid treatments.
Implementation Method 1
selective catalytic reduction (SCR) technology is commonly applied to combustion-derived flue gases for removal of nitrogen oxides when passed through a catalytic reactor. The denitrification reaction comprises the reaction of nitrogen oxide species in the gases, such as nitrogen oxide (NO) or nitrogen dioxide (NO2), with a nitrogen containing reductant, such as ammonia or urea, resulting in the production of diatomic nitrogen (N2) and water.
Data Source
AI summary
The present invention, in some embodiments, provides catalyst modules and/or catalytic reactors having increased effective catalyst cross-sectional areas. In some embodiments, a catalyst module comprises a fluid stream inlet side comprising a plurality of first catalyst bodies and a plurality of first ducts and a fluid stream outlet side comprising a plurality of second catalyst bodies and a plurality of second ducts, wherein the first ducts are a fluid stream inlet to the second catalyst bodies and the second ducts are a fluid stream outlet for the first catalyst bodies.