Modular Catalyst Unit for Bag Filter Fume Cleaning
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Solution Overview
Problem
Existing fume cleaning devices that combine acid pollutant removal and nitrogen oxide destruction in a single unit via catalytic routes are costly, inefficient due to short gas contact time, require high operating temperatures, and have complex maintenance procedures, with catalyst poisoning leading to frequent replacements and increased labor costs.
Innovation Solution
An integrated device with a structured catalyst positioned downstream and above filter bags within the same casing, allowing for homogeneous gas redistribution and reduced catalyst size, combined with horizontal movement of catalyst unit elements for easy maintenance, and pulse jet cleaning capabilities to prevent fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a catalytic bag filter is used to combine acid pollutant removal and nitrogen oxide destruction in a single unit, then the device integration is improved, but the gas contact time with the catalyst is too short and operating temperature must be increased
Solution Approach 1:
The catalyst is divided into multiple modular units that can be arranged in series within the bag filter, increasing the total catalyst contact area and gas contact time without requiring a single large catalyst block that would hinder bag cleaning operations
Solution Approach 2:
The catalyst units are positioned in the vertical dimension within the bag filter structure, utilizing the height of the filter housing to extend the gas-catalyst interaction path, thereby increasing contact time without expanding the horizontal footprint
2Productivity
If small blocks of catalyst are placed in honeycomb arrangement inside bag filter outlets, then catalytic denitrification is achieved, but the catalyst hampers the blowing power of air jet and limits pulse jet cleaning efficiency
Solution Approach 1:
The catalyst units are designed to be removable from the bag filter housing, allowing them to be extracted when bag cleaning is required, thus eliminating the negative impact of catalyst presence on pulse jet cleaning while maintaining catalytic function during normal operation
Solution Approach 2:
The catalyst units are made movable within the housing rather than fixed, allowing dynamic repositioning or removal to facilitate bag cleaning operations, and can be easily reinstalled after cleaning is completed
3Stability of the object's composition
If catalyst unit elements are positioned far from the bag filter outlet to allow reagent distribution, then homogeneous gas-reagent mixing is achieved, but the total height of the casing becomes very high and maintenance becomes complicated
Solution Approach 1:
The catalyst system is segmented into multiple compact units that can be arranged in a space-efficient manner within the existing housing height, eliminating the need for a single distant catalyst position while still allowing adequate reagent distribution space
Solution Approach 2:
The upper part of the housing serves multiple functions: it contains the catalyst units, allows reagent injection and distribution, and provides access for maintenance operations, eliminating the need for separate spaces for each function and reducing overall housing height
4Reliability
If the catalyst and bag assembly must be changed when the catalyst is poisoned, then catalytic activity is maintained, but the maintenance cost and labor intensity increase
Solution Approach 1:
The catalyst is divided into separate removable units that can be independently replaced without removing the entire bag filter assembly, significantly reducing maintenance labor intensity while ensuring catalytic activity is maintained
Solution Approach 2:
The modular catalyst units can be easily removed, replaced, or regenerated independently, allowing for cost-effective maintenance by replacing only the poisoned catalyst units rather than the entire assembly
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 solution results in a compact, economical, and efficient fume cleaning system with extended catalyst lifetime, reduced maintenance complexity, and lower operational costs, while maintaining high denitrification performance and acid pollutant removal efficiency.
Implementation Method 1
the fumes to be purified are first filtered, their acid pollutants being removed by passing through the filter bags
Implementation Method 2
denitrified by passing through a structured catalyst... the destruction of nitrogen oxides via catalytic route
Implementation Method 3
the means inserted in the casing between the filter bags and catalyst to blow under pressure into the outlet of the filter bags in order to de-clog them
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
This device (10) comprises a fume circulation casing (16) inside which there are integrated both a filter (12) having vertical filter bags (18) and a channel-structured catalyst (14), the channels of the catalyst having a hydraulic diameter of less than 6 mm, the fumes to be cleaned (1 ) passing through the filter bags and then the catalyst. Inside the casing, the catalyst is positioned above the outlet of the filter bags and is divided into unit elements (22) that are placed horizontally side by side inside the casing and are vertically removable from the casing. This purifying device is made compact, economical, practical and efficient by distancing the catalyst from the outlet of the filter bags by a vertical distance (d) of between 2.5 and 6 times the hydraulic diameter of the filter bags, and the unit elements are positioned side by side inside the casing being arranged successively in several rows in a horizontal direction (X), each unit element being equipped with moving means (24) for moving the corresponding unit element in this horizontal direction relative to the casing.