Dual Grid Catalyst Basket for Ammonia Oxidation
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Solution Overview
Problem
Existing ammonia oxidation catalyst baskets with single support grids face issues like gapping, catalyst compression, and seal interruptions due to the interaction between primary and secondary catalysts, leading to process inefficiencies and greenhouse gas emissions.
Innovation Solution
A dual support grid design where a first grid supports the primary catalyst independently of a second grid supporting the secondary catalyst, preventing interference and maintaining the primary catalyst's flatness to ensure a secure seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single support grid is used to hold both primary and secondary catalysts, then device complexity is reduced, but catalyst interaction causes gapping, compression, and seal interruptions leading to process reliability deterioration
Solution Approach 1:
The single support grid is divided into two separate support grids: a first support grid for the primary catalyst and a second support grid for the secondary catalyst. This segmentation allows each catalyst to be independently supported, preventing the interaction problems (gapping, compression, seal interruptions) that occur when both catalysts share a single support structure.
2Object-affected harmful factors
If secondary catalyst is added to eliminate N2O emissions, then environmental performance is improved, but catalyst compression reduces fill height and interrupts primary catalyst seal
Solution Approach 1:
By separating the support structures for primary and secondary catalysts into independent grids, the secondary catalyst can be added to eliminate N2O emissions without causing compression issues that would reduce fill height and interrupt the primary catalyst seal. Each catalyst maintains its own support and positioning.
3Object-generated harmful factors
If secondary catalyst is installed underneath primary catalyst, then N2O abatement function is achieved, but catalyst movement causes gapping at the sidewall interface
Solution Approach 1:
The independent support grids prevent catalyst movement-induced gapping by providing separate, stable foundations for each catalyst layer. The first grid supports the primary catalyst and the second grid supports the secondary catalyst, eliminating the gapping that occurs at the sidewall interface when catalysts are coupled on a single grid.
4Reliability
If primary and secondary catalysts are supported independently, then process reliability is improved by preventing gapping and compression issues, but device complexity increases with dual support grids
Solution Approach 1:
The dual support grid structure segments the support function into two independent systems, one for each catalyst type. This segmentation resolves the technical contradiction by providing the reliability benefits of independent support while maintaining a relatively simple overall structure that follows the existing catalyst basket design.
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 dual grid design allows both catalysts to operate independently, reducing gapping and compression issues, maintaining the primary catalyst's seal, and enhancing the overall efficiency of nitric acid production by minimizing greenhouse gas emissions.
Implementation Method 1
ammonia oxidation catalyst basket, along with some heat exchange equipment. Historically over the last approximately 60 years, ammonia oxidation catalyst baskets have been designed with a single support grid
Implementation Method 2
The secondary catalyst is typically installed underneath the primary catalyst. As the NOx is produced by the primary catalyst, the NOx passes over the secondary catalyst that selectively destroys the N2O.
Data Source
AI summary
An ammonia oxidation catalyst basket design has two support grids. A first grid supports the primary catalyst and a separate, second grid supports the secondary catalyst. This dual grid design separates the two catalysts, and enables the catalysts to be independent of each other. Any interruption in the primary or the secondary catalyst does not impede or adversely impact on the structure or function of the other catalyst.