Catalytic Refractory Heating Appliance with Metal Oxide Framework
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Solution Overview
Problem
Existing refractory materials in heating appliances are passive and do not facilitate catalytic reactions, limiting their ability to efficiently manage combustion byproducts and reduce emissions.
Innovation Solution
A catalytic refractory heating appliance is developed using a nitride bonded silicon carbide material with modified porosity to allow ionic oxygen passage, coated with a metal oxide framework catalyst, which enables active catalytic capabilities such as reducing carbon monoxide to methane and absorbing sulfur compounds, and further enhanced with a metallic vapor coating for extended regeneration cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional refractory materials are used in heating appliances, then the structure can withstand extreme temperatures, but the material cannot facilitate catalytic reactions to manage combustion byproducts
Solution Approach 1:
The patent applies composite materials by combining traditional nitride-bonded silicon carbide refractory material with metal oxide framework catalyst coatings. This creates a composite structure where the silicon carbide provides thermal stability and structural integrity, while the metal oxide framework coating enables catalytic reactions to manage combustion byproducts such as carbon monoxide and sulfur compounds.
Solution Approach 2:
The patent utilizes porous materials by incorporating a metal oxide framework catalyst coating with controlled porosity onto the refractory surface. The porous structure allows ionic oxygen to pass through while providing active sites for catalytic reactions, enabling the refractory material to facilitate chemical transformations without compromising its thermal resistance.
2Object-generated harmful factors
If a catalyst coating is applied to the refractory material, then catalytic reactions can be induced to reduce emissions, but the complexity of the appliance structure increases
Solution Approach 1:
The patent merges the catalytic function with the existing refractory structure by applying the metal oxide framework catalyst coating directly onto the silicon carbide refractory material. This integration combines the structural and catalytic functions into a single component, reducing emissions through catalytic reactions without requiring separate catalytic converters or additional complex systems.
Solution Approach 2:
The refractory material is transformed into a multi-functional component that simultaneously provides thermal insulation, structural support, and catalytic activity. The metal oxide framework coating enables the refractory to perform multiple functions: withstanding high temperatures, maintaining structural integrity, and facilitating catalytic reactions to convert harmful emissions into less harmful substances.
3Adaptability or versatility
If the refractory material is made porous to allow ionic oxygen passage, then catalytic reactions can occur, but the heat loss resistance may be reduced
Solution Approach 1:
The patent applies local quality by creating a porous metal oxide framework catalyst coating only on the surface of the refractory material where catalytic reactions are needed, while maintaining the dense, heat-resistant bulk silicon carbide structure. This localized porosity allows ionic oxygen to reach the catalytic sites without significantly compromising the overall heat loss resistance of the refractory material.
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 solution enhances the refractory material's ability to actively participate in catalytic reactions, achieving up to 80% reduction of carbon dioxide to carbon monoxide and extending the catalyst's longevity through efficient regeneration, thereby improving secondary heat recovery and emission reduction.
Implementation Method 1
Due to the firing process the resulting silicon carbide material has a porosity that permits ionic oxygen to pass through the refractory materials
Implementation Method 2
A catalyst is something which induces a reaction yet is not consumed in the process... a fire tube can be coated with a metal oxide framework (MOF) catalyst whereby carbon dioxide and sulfur compounds can be directly absorbed, or carbon monoxide is reduced to methane
Implementation Method 3
The metal vapor coating is combined with the catalyst coating... A metallic vapor coating is positioned on the silicon carbide refractory material
Data Source
AI summary
A catalytic refractory heating appliance includes a body formed from a silicon carbide refractory material having a porosity that permits ionic oxygen to pass through the refractory material. The body defines a gas flow channel. A catalyst coating is on a surface of the refractory material of the body, whereby the refractory material becomes an active component with catalytic capability. For example, when the catalytic refractory heating appliance is a fire tube carbon dioxide and sulfur compounds can be directly absorbed, or carbon monoxide is reduced to methane.