Modular Endogas Generator with Parallel Catalytic Tubes
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Solution Overview
Problem
Existing endogas generators lack modularity in reducing flow rates without compromising the optimal composition of endogas, leading to inefficiencies and potential catalyst damage, and are unable to produce enriched atmospheres with higher CO and H2 percentages required for certain metal treatments.
Innovation Solution
A modular endogas generator with a catalytic reactor consisting of multiple parallel tubes using noble metal oxide catalysts, allowing independent regulation of each tube's feed and operation, enabling flexible flow rate adjustment and catalyst regeneration during operation, while maintaining optimal endogas composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flow rate of endogas is reduced below nominal capacity in conventional generators, then productivity decreases, but the composition of endogas deteriorates from optimal levels
Solution Approach 1:
The catalytic reactor is divided into multiple independent catalytic tubes (at least three) arranged in parallel, each capable of independent operation. This segmentation allows selective activation/deactivation of individual tubes to maintain optimal composition at various flow rates, resolving the contradiction between productivity reduction and composition stability.
2Ease of manufacture
If nickel-based catalysts are used to produce endogas, then manufacturing cost is reduced, but the spatial speed and selectivity towards CO and H2 are insufficient
Solution Approach 1:
The patent changes the catalyst material parameter from nickel-based to noble metal-based (platinum, palladium, rhodium, or their oxides). This parameter change dramatically increases spatial speed from less than 4000 h-1 to greater than 4000 h-1, and improves selectivity towards CO and H2 production, justifying the higher manufacturing cost through enhanced performance.
3Productivity
If the diameter of catalytic retorts is increased to provide sufficient catalyst volume, then productivity increases, but device complexity and space requirements increase
Solution Approach 1:
Instead of using a single large-diameter retort, the patent segments the catalyst volume into multiple smaller-diameter catalytic tubes arranged in parallel. This segmentation maintains sufficient total catalyst volume for high productivity while simplifying individual tube structures and reducing overall device complexity.
4Productivity
If conventional endogas generators operate at reduced flow rates, then productivity decreases, but catalyst regeneration capability is lost
Solution Approach 1:
The patent enables continuous catalyst regeneration by allowing non-operational catalytic tubes to be regenerated in-situ while other tubes continue producing endogas. This maintains continuous useful action of the system, combining reduced productivity mode with ongoing catalyst maintenance capability.
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
Enables production of endogas with increased CO and H2 percentages, maintaining optimal composition even at reduced flow rates, and allows for continuous operation with catalyst regeneration, reducing downtime and operational costs.
Implementation Method 1
each said catalytic tube contains, at least in one tube section, a catalyst based on noble metal oxides for partial oxidation of an air-methane (or other hydrocarbon) or air-methane-carbon dioxide (or other hydrocarbon) mixture
Implementation Method 2
the result of an endothermic reaction of incomplete combustion between air and methane (or another hydrocarbon), conducted in the absence of oxygen and in the absence of water/steam, to form reducing substances such as CO
Implementation Method 3
a heating chamber that supplies heat to a catalytic reactor, placed inside it
Implementation Method 4
followed by a heat exchanger, usually gas/water, to rapidly cool the reaction products so as to avoid that the reaction proceeds further forming CO2 in high quantities
Implementation Method 5
The endogas is the result of an endothermic reaction of incomplete combustion between air and methane (or another hydrocarbon)
Data Source
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AI summary
A description is given of an endogas generator (100) which comprises a catalytic reactor inside a heating chamber (1) where the catalytic reactor consists of at least three catalytic tubes (4) in the form of a tube bundle, each containing a noble metal oxide-based catalyst for the partial oxidation of a binary air-methane (or another hydrocarbon) or ternary air-methane-CO2 (or another hydrocarbon) mixture, said generator providing moreover an automated system (200) with two mixing and control units (501;502) independent one of the other, for controlling singly shut-off valves (6in) placed upstream of said catalytic tubes so as to be able to manage simultaneously the flow rate of endogas, the possible CO enrichment of the endogas and the number of catalytic tubes (4) in regeneration.