Honeycomb Monolith Structure with Rounded Polygonal Channels
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Solution Overview
Problem
Honeycomb monolith structures with high corner density and straight corners suffer from low chemical conversion, increased pressure drop, and are prone to plugging and fouling with particulate matter in gas streams, particularly in flue gases containing varying particle sizes.
Innovation Solution
A honeycomb monolith structure with elongated polygonal channels, such as hexagons and pentagons, featuring more than 50% internal angles greater than 90 degrees and a cell aspect ratio greater than 1.5, with rounded corners, arranged in a closest packing configuration to reduce pressure drop and clogging, while maintaining chemical conversion rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If honeycomb monolith structures with straight corners and high corner density are used, then structural strength is improved, but chemical conversion decreases and pressure drop increases
Solution Approach 1:
The patent applies curvature by rounding the corners of the monolith channels instead of using sharp straight corners. This curvature modification reduces flow resistance and improves chemical conversion while maintaining structural integrity through controlled corner rounding rather than complete elimination of corner features
2Strength
If honeycomb monolith structures with straight corners and high corner density are used, then structural strength is improved, but resistance to plugging and fouling decreases
Solution Approach 1:
Rounded corners create smoother flow paths that prevent particulate matter from accumulating and plugging the channels. The curved geometry eliminates sharp corners where particles would otherwise collect, thereby improving resistance to fouling while maintaining adequate structural strength through controlled rounding
3Ease of manufacture
If traditional square channel designs are used, then manufacturing simplicity is improved, but pressure drop increases and open frontal area decreases
Solution Approach 1:
The patent transitions from symmetric square channels to asymmetric hexagonal channels with specific angle configurations (120-degree angles). This asymmetric geometry optimizes flow characteristics and increases open frontal area while remaining compatible with standard extrusion manufacturing processes through appropriate die design
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
Honeycomb monolith structure, especially for use as catalyst or support for a catalyst in selective catalytic reduction (SCR) of nitrogen oxides, comprising: a plurality of cell walls defining a plurality of polygonal channels, the plurality of cell walls and channels extending in parallel along a common direction from an entrance end to an outlet end of the structure in the fluid flow direction. The transversal cross section of a polygonal channel has the shape of a convex polygon in closest packing, wherein more than 50 % of the internal angels between two adjacent walls of the convex polygon are above 90 degrees and wherein the cell aspect ratio LL/LS is greater than 1.5. The monolith structure has an outer row of polygons in shifted direction perpendicular to each other at the two side edges of the monolith which are parallel to the longest direction of the cells/channels.