Flat-Plate Catalyst Wear Ratio Measurement Device
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Solution Overview
Problem
Conventional methods for measuring the wear ratio of flat-plate catalysts with bends are prone to large errors due to the irregular shape and bending of the catalysts, making it difficult to accurately determine when the catalysts should be scrapped.
Innovation Solution
A device comprising a powder separation unit with counter-rotating rollers and a powder recovery unit with multi-stage filtration is used to separate and recover flat-plate catalyst powder, allowing for accurate wear ratio determination through weight comparison.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement methods are used for flat-plate catalysts with bends, then the measurement process is simple, but the measurement precision deteriorates due to large errors at bend areas
Solution Approach 1:
The patent replaces conventional mechanical measurement methods with a powder separation and weighing system. The catalyst plate is crushed to separate coating powder from the metal mesh substrate, and the powder is weighed to determine wear ratio. This substitution eliminates the problem of measuring bends and irregular shapes, achieving high measurement precision without complex measurement devices.
Solution Approach 2:
The patent changes the measurement parameter from direct geometric measurement of wear areas to mass measurement of separated coating powder. By transforming the measurement from spatial dimensions to mass dimension, the method achieves accurate wear ratio determination regardless of the catalyst plate's bent shape or wear pattern irregularities.
2Quantity of substance
If the catalyst plate is crushed to separate powder, then the powder separation is effective, but the catalyst powder may be lost during the process
Solution Approach 1:
The patent uses a vacuum system with a vacuum pump to create negative pressure during the powder separation and collection process. The vacuum draws the crushed catalyst material through a collection system, ensuring that coating powder is captured rather than lost. This pneumatic approach effectively prevents powder loss while maintaining efficient separation.
Solution Approach 2:
The patent implements a comprehensive recovery system that collects coating powder through vacuum suction and filters it through a collection bag. The metal mesh substrate is separated and can be reused, while the recovered coating powder is preserved for analysis. This approach maximizes the recovery rate of valuable catalyst materials.
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
The device significantly reduces measurement errors and improves the accuracy of wear ratio determination, enabling more reliable evaluation of flat-plate catalysts and optimizing catalyst resource utilization.
Implementation Method 1
an induced draft fan, a powder recovery inlet, a cyclone outlet, a primary filter, a movable sealing sheet, a secondary filter, a cyclone passage and a recovery shell
Implementation Method 2
a powder separation unit and a powder recovery unit; the powder separation unit including a driving motor, counter-rotating rollers
Data Source
AI summary
A device for separating and recovering flat-plate catalyst powder and a method for determining a wear ratio are provided. The device includes a powder separation unit and a powder recovery unit, a powder accumulation bin is respectively connected with a shell and a catalyst powder outlet, a cyclone outlet is configured on an inner side of a recovery shell, and a primary filter and a secondary filter are configured on an inner side wall of the recovery shell.