Honeycomb Catalyst Body with Localized Particle Adhesion
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Solution Overview
Problem
Existing honeycomb catalyst bodies face challenges in effectively reducing pressure loss and production costs while maintaining efficient particulate matter collection and catalyst support, particularly during regeneration, due to non-uniform combustion heat and excessive catalyst usage.
Innovation Solution
A modified honeycomb catalyst body with a porous partition wall structure, where particles adhere to the inner surface of pores in specific areas to increase heat capacity and reduce catalyst amount, featuring a first area with modified and a second area with unmodified partition walls, allowing for selective catalyst support and reduced porosity, thereby controlling pressure loss and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If particles are caused to adhere to the inner surface of pores in the downstream area to increase heat capacity, then non-uniformity of combustion heat is suppressed, but the rate of increase in pressure loss increases and production cost increases due to unnecessary catalyst support
Solution Approach 1:
The invention applies local quality by creating two distinct areas with different properties: the first area (upstream) has particles adhering to pore inner surfaces to increase heat capacity and suppress temperature non-uniformity, while the second area (downstream) has unmodified partition walls with normal porosity to maintain low pressure loss. This spatial differentiation of properties allows the system to achieve thermal stability without the penalty of increased pressure loss throughout the entire structure.
2Temperature
If particles are caused to adhere to the inner surface of pores in the downstream area, then heat capacity is increased, but production cost increases due to unnecessary catalyst support
Solution Approach 1:
The invention reduces production cost by applying the particle adhesion modification only locally in the first area where heat capacity enhancement is most needed for suppressing temperature non-uniformity. The second area maintains normal porosity without particles, avoiding unnecessary catalyst support and associated costs in regions where heat capacity enhancement would provide minimal benefit.
3Stability of the object's composition
If the partition wall porosity is reduced to increase heat capacity, then temperature uniformity is improved, but catalyst support efficiency decreases
Solution Approach 1:
The invention optimizes catalyst support efficiency by maintaining normal partition wall porosity in the second area (downstream), which provides adequate surface area and accessibility for catalyst support. The first area (upstream) has reduced effective porosity due to particle adhesion, but this is acceptable since the primary function there is heat capacity enhancement rather than catalyst support.
4Temperature
If the partition wall porosity is reduced, then heat capacity is increased, but the filter becomes more difficult to produce
Solution Approach 1:
The invention simplifies manufacturing by applying the porosity reduction (via particle adhesion) only to the first area rather than the entire partition wall. This localized approach reduces the overall manufacturing complexity compared to producing a uniformly low-porosity structure, while still achieving sufficient heat capacity enhancement in the critical upstream region.
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 modified structure effectively collects and removes particulate matter, reduces catalyst usage, and decreases pressure loss, while being easier to produce, thus enhancing the overall efficiency and cost-effectiveness of the catalyst body.
Implementation Method 1
a number of particles adhering to an inner surface of pores formed in the modified partition wall
Implementation Method 2
a catalyst that is supported in a given area of the partition wall
Implementation Method 3
exhaust gas that has entered the filter through one end face passes through the porous partition wall (filtration layer), and is discharged through the other end face
Implementation Method 4
an oxidation catalyst may be disposed between fuel adding means and a ceramic honeycomb filter. With the oxidation catalyst, exhaust gas is oxidised and the temperature of the exhaust gas is raised by the oxidation reaction
Implementation Method 5
it is necessary to burn and remove PM deposited in the filter in order to reduce the pressure loss
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A honeycomb catalyst body includes a modified honeycomb structure that includes a porous partition wall having a number of pores,, and a catalyst that is supported in a given area of the partition wall. The modified honeycomb structure includes a first area that includes a modified partition wall and includes at least part of one end face, a number of particles adhering to an inner surface of pores formed in the modified partition wall, and a second area that includes an unmodified partition wall and includes at least part of the other end face, the particles not adhering to the unmodified partition wall, the modified partition wall having a porosity lower than that of the unmodified partition wall, and an amount of the catalyst supported in the first area per unit volume being smaller than that of the second area.