Element Frame Mat and Locking Cut-outs for Catalyst Stability
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Solution Overview
Problem
Current element frames in catalyst modules for treating exhaust gases from stationary combustion systems face challenges with mechanical stability due to vibrations and shock, leading to potential destruction of monoliths, and lack a cost-effective solution for sealing and cushioning between monoliths and the frame, resulting in reduced catalyst exposure and efficiency.
Innovation Solution
The design incorporates a rectangular or square element frame with opposing walls, a mat positioned between monoliths and walls for sealing and cushioning, and locking elements with cut-outs to increase catalyst exposure, while allowing for connection of multiple frames to minimize bypass and enhance mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional element frames without mats are used, then the structure is simpler and cheaper, but mechanical stability against vibrations and shock is poor, leading to monolith destruction
Solution Approach 1:
A mat is introduced as an intermediary element between the monolith and the element frame walls. This mat serves multiple functions: it provides sealing to prevent gas bypass, offers cushioning against vibrations and shock, and protects the monolith from direct contact with the frame walls. The mat is held in place by protrusions on the frame walls, creating a buffered interface that resolves the contradiction between mechanical stability and structural simplicity.
2Productivity
If locking elements without cut-outs are used, then the structure is simpler, but catalyst exposure to exhaust gases is reduced, lowering treatment efficiency
Solution Approach 1:
The locking elements are designed with cut-outs at specific locations where they would otherwise block exhaust gas flow. These cut-outs create localized openings that allow exhaust gases to reach the catalyst coating on the monolith surface. The locking elements maintain their structural function of securing the monolith while the cut-outs provide localized gas flow paths, resolving the contradiction between structural simplicity and catalyst exposure efficiency.
3Productivity
If multiple element frames are connected to minimize bypass, then pollutant treatment efficiency improves, but the system becomes more complex and harder to assemble
Solution Approach 1:
The catalyst system is divided into multiple separate element frames, each containing its own monolith and mat assembly. These modular frames can be independently manufactured and then connected together to form a complete catalyst module. The segmentation allows for optimized individual frame design while enabling flexible assembly of multiple frames to treat large volumes of exhaust gas, resolving the contradiction between treatment efficiency and manufacturing ease.
4Productivity
If mats are not used between monolith and walls, then the structure is simpler and cost lower, but sealing is insufficient leading to gas bypass and reduced catalyst effectiveness
Solution Approach 1:
A mat is introduced as an intermediary element between the monolith and the element frame walls. This mat serves multiple functions: it provides sealing to prevent gas bypass, offers cushioning against vibrations and shock, and protects the monolith from direct contact with the frame walls. The mat is held in place by protrusions on the frame walls, creating a buffered interface that resolves the contradiction between mechanical stability and structural simplicity.
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 improves mechanical stability against vibrations, increases catalyst exposure to exhaust gases, and allows for efficient treatment of pollutants like NOx, CO, and HC, while maintaining a cost-effective solution for sealing and cushioning.
Implementation Method 1
at least one catalyst effective in reducing the concentration of one or more gases in the exhaust gas
Implementation Method 2
at least one mat between the monolith and each adjacent wall
Data Source
AI summary
An element frame for holding monoliths containing catalysts in the flow of exhaust gases from a combustion source, the element frame comprising two pairs of opposing walls, wherein the walls form a rectangular or square shape, an interior formed by the walls, an inlet end, an outlet end, at least one locking element, at least one mat and at least one monolith comprising an inlet, an outlet, four sides and at least one catalyst effective in reducing the concentration of one or more gases in the exhaust gas, wherein the at least one mat and the at least one monolith being positioned in the interior of the element frame so that there is at least one mat between the monolith and each adjacent wall, each locking element extending across the inlet end or outlet end of the element frame and being connected to two opposite sides of the element frame.