Modular Catalyst Support Basket for Ammonia Burner Heat Stress
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Solution Overview
Problem
Existing catalyst support systems for ammonia oxidation burners are susceptible to structural integrity issues due to thermal stress, leading to deformation, cracks, and gas bypass routes, which affect the distribution and effectiveness of the N2O secondary abatement catalyst.
Innovation Solution
A modular basket design with gas-permeable floors and supporting frames, connected by radial and circumferential joints, allowing limited displacement between modules to accommodate thermal elongation, and supported by cooling tubes for additional stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-piece basket or large-section basket is used to support the N2O secondary catalyst, then the structural simplicity is maintained, but thermal elongation compensation is insufficient leading to deformation and failure
Solution Approach 1:
The basket is divided into multiple small modular sections, each capable of independent thermal expansion and contraction. This segmentation allows the structure to accommodate thermal elongation without deformation or failure, resolving the contradiction between structural simplicity and thermal reliability.
2Strength
If the basket is made from rigid materials to withstand high temperature and pressure, then mechanical strength is improved, but thermal elongation induces deformation and cracking
Solution Approach 1:
By dividing the rigid basket into multiple small modular sections connected by flexible joints, each section can expand and contract independently under thermal stress. This maintains the mechanical strength needed to withstand high temperature and pressure while preventing the deformation and cracking that would occur in a monolithic rigid structure.
3Stability of the object's composition
If the basket is tightly fixed to prevent displacement, then positional stability is improved, but thermal stress causes cracks and structural failure
Solution Approach 1:
The basket is segmented into multiple modules that can move independently relative to each other. This allows the structure to maintain overall positional stability while accommodating thermal expansion and contraction through localized movements at the module interfaces, preventing cracks and structural failure.
Solution Approach 2:
The basket incorporates dynamic elements that allow controlled movement and adjustment in response to thermal stress. The modular design with flexible connections enables the structure to adapt its configuration under varying thermal conditions, maintaining stability without inducing cracking.
4Productivity
If the basket floor surface is made smooth and continuous to ensure uniform gas flow, then flow distribution is improved, but thermal stress causes bulges and waves that create bypass routes
Solution Approach 1:
The basket floor is divided into multiple small modular sections, each maintaining a smooth continuous surface for uniform gas flow. The segmentation allows each module to expand and contract independently under thermal stress without creating bulges or waves that would compromise surface integrity or create bypass routes.
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 modular design effectively distributes thermal stress, reduces catalyst displacement, minimizes gas bypass, and enhances the operational life of the ammonia oxidation burner by maintaining uniform gas flow and catalyst distribution.
Implementation Method 1
The metallic ring and the carrier plate are subject to a considerable thermal elongation and must be able to withstand the weight and the pressure drop of the catalytic gauze and of the basket which contains the abatement catalyst.
Implementation Method 2
The ammonia oxidation gas is cooled in one or more heat exchangers to push the conversion of NO into NO2
Implementation Method 3
ammonia and an oxygen containing-gas, such as air or pure oxygen, are catalytically reacted in a burner at high temperature over a catalytic gauze
Implementation Method 4
The product of the oxidation of ammonia is a gas mixture that contains nitrogen monoxide NO and nitrogen dioxides NO2 as major components
Implementation Method 5
the N2O contained in the ammonia gas can be removed directly in the ammonia burner by flowing the gas mixture through a catalyst suitable to decompose N2O into nitrogen and oxygen
Implementation Method 6
a catalyst suitable to decompose N2O into nitrogen and oxygen
Data Source
AI summary
A catalyst support system for an ammonia oxidation burner, comprising a catalytic gauze for oxidation of ammonia; a basket connected to a supporting ring for containing an inert and/or a catalyst for removing N2O from a gaseous effluent of said catalytic gauze; said basket has a modular structure including a plurality of modules, wherein each module includes a gas-permeable surface and a supporting frame, wherein each module is connected to adjacent modules by connections adapted to allow a limited displacement between modules, wherein only outer modules forming the periphery of the basket are connected to said supporting ring.