Floating Support Grid for Horizontal Ammonia Converter Catalyst Beds
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Solution Overview
Problem
The existing support grid systems in horizontal ammonia converter baskets experience failures due to excessive thermal stresses and resistance to thermal expansion, leading to structural issues and catalyst containment problems during rapid temperature changes.
Innovation Solution
A floating support grid system with floating connections and gaps to accommodate thermal expansion movements of support beams and profile wire screen panels, connected to the horizontal ammonia converter basket through non-welded methods, ensuring flexibility and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the support grid system uses welded profile wire screen panels to beams for structural stability, then the structural strength is improved, but the thermal expansion resistance deteriorates causing excessive stresses and failure during rapid temperature changes
Solution Approach 1:
The support grid system is divided into separate components (profile wire screen panels and beams) that are not permanently welded together. Each component can independently expand and contract during thermal cycles, preventing stress buildup while maintaining structural integrity through floating connections that allow controlled movement.
Solution Approach 2:
The connection between profile wire screen panels and beams is made dynamic rather than static. Floating connections enable the structure to adapt to thermal expansion movements, allowing the components to move relative to each other in response to temperature changes while maintaining operational stability.
2Stability of the object's composition
If the support grid system uses fixed connections to maintain structural stability, then the structural stability is improved, but the adaptability to thermal expansion deteriorates leading to resistance and excessive stresses
Solution Approach 1:
The support grid system employs floating connections that provide dynamic stability. These connections maintain structural stability during normal operation while allowing the necessary movement during thermal expansion, combining both stability and adaptability in a single design approach.
Solution Approach 2:
The connection method changes from fixed to floating, altering the degrees of freedom in the system. This parameter change enables the structure to accommodate thermal expansion movements while maintaining operational stability, as the floating connections allow controlled movement without compromising overall structural integrity.
3Manufacturing precision
If the profile wire screen panels are rigidly connected to beams, then the manufacturing precision is improved, but the thermal expansion accommodation deteriorates causing panel sticking and containment issues
Solution Approach 1:
The profile wire screen panels and beams are treated as separate, movable segments rather than a rigid assembly. Floating connections maintain precise alignment during manufacturing and assembly while allowing independent thermal expansion movements during operation, preventing panel sticking and maintaining catalyst containment integrity.
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 effectively withstands high temperature fluctuations, preventing structural failure and maintaining catalyst containment, thus enhancing the durability and efficiency of ammonia production.
Implementation Method 1
the support beams are required to expand and move within the catalyst bed. Such expansions and movements may be resisted by the catalyst leading to resistance and excessive stresses in the support grid system
Data Source
AI summary
A floating support grid system including a plurality of support beams and a plurality of profile wire screen panels wherein the support beams are connected to the profile wire screen panels via one or more first floating connections, wherein the support beams are configured to connect to a horizontal ammonia converter basket via one or more second floating connections, and wherein at least some the profile wire screen panels are configured to connect to a horizontal ammonia converter basket via one or more third floating connections, wherein each of the first, second, and third floating connections independently defines one or more gaps to accommodate movement caused by thermal expansion.