Flat Deflector Plates for NOx Mixing in Exhaust Systems
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Solution Overview
Problem
Existing NOx abatement systems for stationary combustion systems are complex, costly, and prone to faults due to the complexity of mixing and distribution systems, which affects the efficiency of NOx reduction.
Innovation Solution
A mixing system with flat deflector plates positioned downstream from the injection points of the NOx reducing agent, which induces turbulent flows to ensure intensive mixing of the reducing agent with the exhaust gases while maintaining a low pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If complex mixing systems with multiple parts are used to achieve intensive mixing of reducing agent with exhaust gases, then mixing effectiveness is improved, but device complexity and production cost increase
Solution Approach 1:
The mixing system is segmented into simple functional components: injection lances for reducing agent introduction and flat deflector plates for turbulence induction. Each component performs a single function, avoiding complex multi-functional parts while achieving effective mixing through the coordinated action of these simple segments.
Solution Approach 2:
The system uses simple, inexpensive flat deflector plates instead of complex, expensive mixing apparatus. These simple components can be easily manufactured and replaced if needed, reducing both initial production cost and long-term maintenance expenses while maintaining mixing effectiveness.
2Stability of the object's composition
If complex mixing systems with multiple parts are used to ensure uniform distribution of reducing agent, then mixing homogeneity is improved, but maintenance cost and fault probability increase
Solution Approach 1:
The system divides the mixing function into simple segments: injection lances deliver the reducing agent while flat deflector plates create turbulence for uniform distribution. This segmentation means each simple component can be independently maintained or replaced without affecting the entire system, improving reliability.
Solution Approach 2:
The complex mixing mechanism is extracted and replaced with simple flat deflector plates that rely on fundamental fluid dynamics principles. By removing unnecessary complexity, the system becomes more reliable with fewer potential failure points while maintaining distribution uniformity through the induced turbulent flow patterns.
3Productivity
If deflectors are positioned upstream from injection points to induce turbulence, then mixing intensity is improved, but flow pattern homogenization deteriorates
Solution Approach 1:
The flat deflector plates are positioned downstream from the injection points, creating turbulence after the reducing agent has been introduced. This preliminary mixing approach allows the reducing agent to be injected first, followed immediately by turbulence induction, ensuring both intensive mixing and homogeneous flow pattern development in sequence.
Solution Approach 2:
Instead of positioning deflectors upstream as in conventional systems, this invention inverts the arrangement by placing flat deflector plates downstream from the injection points. This inversion allows the reducing agent to be injected first into a relatively stable flow, then turbulence is induced to mix the components, achieving both mixing intensity and flow homogeneity.
4Productivity
If numerous mixing parts are used to achieve intensive mixing, then mixing effectiveness is improved, but production cost and maintenance cost increase
Solution Approach 1:
The system replaces expensive, complex mixing apparatus with inexpensive flat deflector plates that are simple to manufacture. These simple components can be produced at low cost using standard fabrication processes, significantly reducing production expenses while maintaining effective mixing through induced turbulence.
Solution Approach 2:
The complex mixing mechanism is extracted and replaced with simple flat deflector plates. By removing unnecessary complexity and using only the essential turbulence-inducing function, the system achieves intensive mixing at a fraction of the production cost of conventional complex mixing systems.
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 system achieves efficient and homogeneous mixing of the NOx reducing agent with the exhaust gases, optimizing NOx reduction while reducing production and maintenance costs and minimizing system complexity.
Implementation Method 1
flat deflector plates operatively associated with the injection lances and positioned inside the flow passage downstream from the one or more injection points and in a transverse direction on the exhaust gas flow direction for mixing the NOx reducing agent with the exhaust gas stream by inducing turbulent flows
Data Source
AI summary
The present application relates to abatement processes and systems of nitrogen oxide (NOx) contained in exhaust gases, more in particular produced by stationary burner and combustion systems. The NOx are removed by reduction using a catalyst and a reducing agent that is introduced into the exhaust gases and being mixed therewith. The mixture is then conducted over the catalyst resulting in conversion of the NOx in environmentally neutral N2 and H2O. The present application more in particular relates to a mixing system for such a NOx abatement system to mix the exhaust gases with the reducing agent.