Catalytic Reactor Sheets With Interlocking Flanges
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Solution Overview
Problem
Existing catalytic reactors are inefficient, lack flexibility, and inefficiently use catalytically active material, making them difficult to adapt to various applications and process parameters.
Innovation Solution
A catalytic reactor design featuring a stack of catalytically active sheets with central openings and axially extending flanges, allowing for efficient distribution of reactants and flexible operation across different reactions and process conditions, with the catalytically active material being efficiently utilized by forming a ceramic layer with pores on a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If catalytic reactors use conventional designs with catalytically active nets arranged in series, then the reactor can perform catalytic reactions, but the reactor is inefficient and requires vast amounts of catalytically active material
Solution Approach 1:
The reactor is segmented into multiple catalytically active sheets stacked in the axial direction, with each sheet having a central opening and flanges. This segmentation allows reactants to be distributed across multiple active surfaces simultaneously, increasing overall reaction efficiency while reducing the total amount of catalytic material needed compared to a single large-scale conventional reactor.
Solution Approach 2:
The invention transitions from a conventional two-dimensional net structure to a three-dimensional stacked sheet configuration with axial and radial dimensions. The flanges extend axially into central openings of adjacent sheets, creating a multi-dimensional flow path that increases the effective surface area for catalysis and improves reactant utilization efficiency.
2Adaptability or versatility
If catalytic reactors use conventional designs, then the reactor can operate, but it lacks flexibility and is difficult to dimension according to different applications and process parameters
Solution Approach 1:
The standardized sheet design with central openings and flanges serves multiple functions: it acts as a catalytic surface, a flow distributor, and a structural component. This universal design can be applied across different reactor sizes and applications by simply varying the number of sheets stacked, making the reactor adaptable to various processes while maintaining a consistent, easy-to-dimension modular structure.
Solution Approach 2:
The reactor design allows dynamic adjustment of process parameters by changing the number of sheets in the stack. This modular approach enables the reactor to be easily scaled and adapted to different flow rates, reaction conditions, and application requirements without redesigning the entire system, providing operational flexibility while maintaining structural simplicity.
3Productivity
If catalytic reactors use conventional designs with nets arranged in series, then the reactor can conduct reactions, but the catalytically active material is not used efficiently
Solution Approach 1:
The stacked sheet configuration with interconnected flanges and central openings creates continuous flow paths that ensure reactants continuously contact the catalytic surfaces. This continuous action maximizes the utilization of catalytically active material by preventing dead zones and ensuring all catalytic surfaces are actively engaged in the reaction process, thereby reducing material waste and improving overall efficiency.
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 reactor achieves efficient catalytic reactions with optimized reactant distribution, reducing material usage and enhancing adaptability to diverse applications, leading to improved performance and efficiency in processes like combustion and reforming.
Implementation Method 1
A catalytic reactor comprises a central axis and a stack of catalytically active sheets, wherein the catalytically active sheets are stacked in the axial direction
Data Source
AI summary
A catalytic reactor (22) comprising a central axis (A) and a stack of catalytically active sheets (10), wherein the catalytically active sheets (10) are stacked in the axial direction. Each of the catalytically active sheets (10) comprises a central opening (17) and at least some of the catalytically active sheets (10) comprise an axially extending flange (18) arranged at least partially around said central opening (17), wherein the flange (18) of one catalytically active sheet (10) extends into the central opening (17) of an adjacent catalytically active sheet (10). Disclosed is also a method for providing a catalytic reaction.