Fibrous Substrate Soot Reduction in Hydrocarbon Pyrolysis
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Solution Overview
Problem
In environmental control systems, particularly in spacecraft and submarines, the discharge of carbon dioxide through pyrolysis to produce oxygen leads to the formation of loose soot, which fouls surfaces, decreases air quality, and short-circuits electrical equipment, due to the generation of solid carbon as a byproduct from hydrogen gas production.
Innovation Solution
The use of fibrous substrates with high surface area to volume ratios, configured to maintain chemical and structural stability at high temperatures, to collect and reduce soot formation by promoting carbon deposition on their surfaces, thereby reducing the overall weight and volume of substrates required for a mission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If fibrous substrates with high surface area are used to reduce soot formation, then carbon deposition efficiency is improved, but substrate weight and volume increase
Solution Approach 1:
The patent employs fibrous substrates with controlled porosity and void fraction (30-80%) to achieve high surface area for carbon deposition while maintaining low density. The porous structure allows carbon to deposit on fiber surfaces and within pores, reducing soot formation without requiring excessive substrate mass. The interplay between fiber diameter (1-50 microns), porosity, and void fraction optimizes both soot reduction and weight characteristics.
2Weight of moving object
If substrate void fraction is increased to reduce weight, then substrate weight is reduced, but carbon loading capacity decreases
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: fiber diameter (1-50 microns), porosity (30-80%), void fraction (30-80%), and fiber length (0.1-10 mm) to achieve the desired balance. By adjusting these parameters, the substrate provides sufficient surface area for carbon deposition (maintaining high loading capacity) while keeping the overall substrate density low enough to reduce weight. The key is optimizing the distribution and arrangement of fibers to maximize surface area per unit mass.
3Object-generated harmful factors
If fiber diameter is reduced to increase surface area, then carbon deposition efficiency is improved, but substrate structural strength decreases
Solution Approach 1:
The patent utilizes fibrous substrates made from materials with high strength-to-weight ratios, such as carbon fibers, silica fibers, or ceramic fibers. These composite fibrous structures provide both the high surface area needed for carbon deposition (when fibers are 1-50 microns in diameter) and the structural strength required to maintain integrity at high temperatures (850-1300°C). The fibrous network structure itself provides mechanical strength through the interconnected arrangement of individual fibers.
4Object-generated harmful factors
If substrate surface area is increased to promote carbon deposition, then soot formation is reduced, but substrate volume increases
Solution Approach 1:
The patent creates high surface area within a compact volume by using fine fibers (1-50 microns) arranged in a porous matrix. Rather than expanding substrate volume to increase surface area, the solution concentrates surface area locally through the fibrous structure. The high porosity (30-80%) allows the substrate to maintain low volume while providing extensive internal and external fiber surfaces for carbon deposition, thereby reducing soot formation without increasing overall substrate volume.
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 fibrous substrates effectively reduce soot production, increase carbon loading capacity, and extend the operational life of pyrolysis reactors by optimizing surface area and void fraction, allowing for longer mission durations with reduced substrate mass and volume.
Implementation Method 1
the fibrous substrates include a high deposition surface area for deposited carbon generated from the pyrolysis of the hydrocarbon
Implementation Method 2
a pyrolysis reactor is configured to generate both hydrogen gas and solid carbon from one or more hydrocarbons, such as methane, through pyrolysis
Data Source
AI summary
The disclosure describes a system for generating hydrogen gas from a hydrocarbon through pyrolysis with reduced soot formation and increased carbon loading. The system includes one or more pyrolysis reactors configured to generate the hydrogen gas from the hydrocarbon through pyrolysis. Each pyrolysis reactor of the one or more pyrolysis reactors includes one or more fibrous substrates and a concentration sensor downstream of at least one fibrous substrate of the one or more fibrous substrates. Each fibrous substrate of the one or more fibrous substrates defines a deposition surface for carbon generated from the pyrolysis of the hydrocarbon and includes a plurality of fibers configured to maintain chemical and structural stability between 850° C. and 1300° C. The concentration sensor is configured to measure a concentration of at least one of a hydrocarbon byproduct or a hydrocarbon soot precursor, such as acetylene.