Frustoconical Ringlike Oxide Bodies for Crack-Resistant Compaction
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Solution Overview
Problem
Existing processes for producing annular oxidic shaped bodies by mechanical compaction result in fragile products with high crack formation due to limited interparticulate binding forces, leading to fractures during thermal treatment and increased pressure drop in catalytic reactions.
Innovation Solution
Modifying the geometry of the shaped precursor body to a frustocone shape, which reduces rollering friction between the die bore and the precursor body, allowing for improved mechanical compaction and thermal treatment without significant impact on pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical compaction is used to produce annular oxidic shaped bodies, then the precursor bodies are produced efficiently, but the precursor bodies become fragile with high crack formation due to limited interparticulate binding forces
Solution Approach 1:
The invention changes the geometric parameters of the precursor body by forming a frustoconical shape instead of a cylindrical shape. This parameter change in geometry reduces rollering friction during thermal treatment, thereby maintaining structural integrity and reducing crack formation while preserving production efficiency from mechanical compaction.
2Strength
If the precursor body geometry is modified to frustocone shape, then fracture resistance is improved, but the manufacturing process complexity increases
Solution Approach 1:
The frustoconical shape is formed during the initial mechanical compaction step itself, rather than requiring a separate shaping operation afterward. This preliminary action integrates the geometric modification into the existing manufacturing process, achieving improved fracture resistance without significantly increasing process complexity.
3Ease of manufacture
If conventional cylindrical geometry is used, then the manufacturing process is simple, but rollering friction during thermal treatment causes increased crack formation
Solution Approach 1:
The invention introduces asymmetry in the vertical dimension by creating a frustoconical shape with different diameters at the top and bottom, rather than a uniform cylindrical shape. This asymmetric geometry reduces rollering friction during thermal treatment, significantly decreasing crack formation while remaining compatible with simple manufacturing processes.
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 frustocone geometry significantly reduces fracture formation and maintains the pressure drop advantage, enhancing the integrity and performance of the annular oxidic shaped bodies.
Implementation Method 1
mechanical compaction of a pulverulent aggregate which has been introduced into the fill chamber of a die
Implementation Method 2
Modifying the geometry of the precursor body to a frustocone shape reduces rollering friction
Implementation Method 3
thermal treatment of the ringlike shaped precursor body at a temperature of ≧100° C., in which at least a portion of its constituents is decomposed and/or converted chemically to form at least one gaseous compound
Implementation Method 4
at least a portion of its constituents is decomposed and/or converted chemically to form at least one gaseous compound
Data Source
AI summary
A process for producing a ringlike oxidic shaped body by mechanically compacting a pulverulent aggregate introduced into the fill chamber of a die, wherein the outer face of the resulting compact corresponds to that of a frustocone.