Heat-Exchanging Catalyst Block for Low-Temperature Methane Oxidation
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Solution Overview
Problem
Natural gas engines produce exhaust gases with low temperatures that are below the effective-reduction temperature for palladium and platinum catalysts, leading to inefficient methane removal, and the use of supplemental fuels to heat the exhaust is costly and bulky.
Innovation Solution
A heat exchanging catalyst block that integrates a catalyst with a counter-current heat exchanger functionality, using the heat of reaction to raise the exhaust gas temperature to the effective-reduction temperature for methane oxidation, reducing the need for supplemental fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If exhaust gas temperature is increased to achieve effective methane oxidation, then catalyst effectiveness improves, but additional heating equipment and space are required
Solution Approach 1:
The patent combines the heat exchanger and catalyst support into a single integrated component. The catalyst is deposited on the walls of the heat exchanger channels, merging the thermal management function with the catalytic oxidation function into one unified device, thereby eliminating separate heating equipment
Solution Approach 2:
The heat exchanger structure performs dual functions: it preheats the incoming exhaust gas using heat from the outgoing treated gas, and simultaneously serves as the support structure for the catalyst. This multi-functionality eliminates the need for separate heating equipment and catalyst support
2Reliability
If supplemental fuel is used to heat exhaust gas, then methane oxidation effectiveness improves, but operational cost increases
Solution Approach 1:
The patent recovers waste heat from the outgoing treated exhaust gas and uses it to preheat the incoming exhaust gas. This converts the otherwise wasted thermal energy into a useful resource, reducing the need for supplemental fuel and lowering operational costs
Solution Approach 2:
The system uses its own outgoing hot gas to heat the incoming cold gas, making the heating process self-sufficient. The heat exchanger enables the system to service its own heating needs without external fuel input, reducing operational costs
3Adaptability or versatility
If separate heat exchanger and catalyst are used, then system flexibility is maintained, but device complexity and space requirements increase
Solution Approach 1:
The patent integrates the catalyst support and heat exchanger into a single component, where the catalyst is deposited on the heat exchanger channel walls. This merging reduces the overall volume and space requirements while maintaining the functional flexibility of having both heating and catalytic capabilities
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 efficiently reduces methane emissions with minimal supplemental fuel consumption and space, eliminating the need for separate heat exchangers, thus lowering operational costs and emissions.
Implementation Method 1
The catalyst block includes a catalyst promoter disposed on an inner surface of the catalyst block
Implementation Method 2
oxidizing the methane emissions contained in the exhaust streams
Implementation Method 3
a metal partition wall facilitating heat exchange
Implementation Method 4
exchanging heat between the second gas mixture with the feed gas mixture via a partitioning wall
Data Source
AI summary
An exemplary apparatus includes an inlet tube for receiving and distributing a first gas mixture, an outlet tube for collecting and discharging a treated gas mixture, inlet channels in fluid communication with the inlet tube each receiving a portion of the first gas mixture distributed from the inlet tube, and outlet channels in fluid communication with the outlet tube each supplying a portion of the treated gas mixture to the outlet tube. Each of the inlet channels is separated from an adjacent outlet channel by a metal partition wall facilitating heat exchange. The apparatus includes a catalyst block including incoming channels each in fluid communication with an inlet channel at one end of the incoming channel and outgoing channels each in fluid communication with an outlet channel at one end of the outgoing channel, and a common channel in fluid communication with the inlet channel and the outgoing channel.