Induction Heating Catalyst Support with Magnetic Body Segmentation
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Solution Overview
Problem
Existing induction heating catalyst systems face inefficiencies in activating catalysts near the inlet of the gas flow direction due to insufficient temperature increase, leading to reduced catalyst utilization and increased production costs, especially when using noble metals like Pt.
Innovation Solution
A catalyst support with a honeycomb structure featuring a region without catalysts at the inlet side in the gas flow direction, where magnetic bodies are placed to enhance heating, and a coil surrounding the catalyst support for induction heating, allowing for effective catalyst utilization and improved exhaust gas purification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal particles or metal pieces are provided throughout the cells and caused to generate heat by induction heating, then the catalyst temperature increases, but the temperature in the vicinity of the inlet in the gas flow direction is not sufficiently increased
Solution Approach 1:
The invention divides the catalyst support into multiple layers along the gas flow direction, with magnetic bodies concentrated in the upstream layer (first layer) and catalysts concentrated in the downstream layer (second layer). This segmentation allows induction heating to occur primarily in the upstream region where temperature increase is most needed, while the catalysts are positioned in the downstream region where they can be effectively activated by the heated gas flow.
Solution Approach 2:
The invention extracts the magnetic bodies from the entire cell structure and concentrates them only in the first layer (upstream side), separating the heating function from the catalytic function. This extraction allows the magnetic bodies to generate heat through induction heating without interfering with catalyst performance, while the catalysts are placed in the second layer where they can be effectively activated by the heated exhaust gas.
2Productivity
If catalyst is provided throughout the entire catalyst support, then purification coverage is maximized, but production cost increases due to insufficient utilization of noble metal catalysts
Solution Approach 1:
The invention applies local quality by concentrating catalysts in the second layer (downstream side) where the gas temperature is sufficient for catalyst activation, while leaving the first layer (upstream side) without catalysts. This creates a spatial distribution where each region has the quality needed for its specific function: the upstream region provides heating, and the downstream region provides catalytic purification.
Solution Approach 2:
The invention performs preliminary action by using the upstream layer with magnetic bodies to preheat the exhaust gas through induction heating before the gas reaches the catalyst-containing downstream layer. This preliminary heating action ensures that the catalysts in the second layer receive preheated gas, enabling effective catalytic purification without requiring catalysts throughout the entire support structure.
3Productivity
If induction heating is applied to increase catalyst temperature, then purification rate improves, but temperature distribution becomes uneven with insufficient heating at the inlet region
Solution Approach 1:
The invention introduces asymmetry in the spatial distribution of magnetic bodies and catalysts along the gas flow direction. Magnetic bodies are concentrated in the upstream layer while catalysts are concentrated in the downstream layer, creating an asymmetric configuration that matches the temperature gradient in the system. This asymmetric arrangement allows effective induction heating in the upstream region while providing adequate catalyst activation in the downstream 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
This configuration ensures efficient catalyst activation and reduced production costs by optimizing temperature distribution and catalyst placement, enhancing the purification performance of the induction heating catalyst system.
Implementation Method 1
heating the magnetic bodies by induction heating
Implementation Method 2
heating the magnetic bodies by induction heating to cause the catalyst support to generate heat
Implementation Method 3
heating the magnetic bodies by induction heating
Implementation Method 4
heating the magnetic bodies by induction heating to cause the catalyst support to generate heat
Data Source
AI summary
A catalyst support for induction heating includes: a honeycomb structure including a pillar shaped honeycomb structure portion having: an outer peripheral wall; and a partition wall disposed on an inner side of the outer peripheral wall, the partition wall defining a plurality of cells, each of the cells extending from an end face on an inlet side to an end face on an outlet side in a gas flow direction to form a flow path; a catalyst supported onto an interior of the partition wall; and at least one magnetic body provided within the honeycomb structure, wherein the catalyst support has a region A where the catalyst is not supported, at least on the end face side of the catalyst support on the inlet side in the gas flow direction, and wherein the magnetic body is arranged at least in the region A in the gas flow direction.