Modular Metal Catalyst Support for Large Exhaust Systems
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing catalytic converters face challenges in scaling up to handle large volumes of exhaust gas from large vessels or plants with multiple large-scale internal combustion engines, as conventional ceramic catalyst supports are difficult to manufacture and assemble into large-capacity structures.
Innovation Solution
A large-capacity metal catalyst support system comprising unit blocks with hollow cells aligned in a polygonal structure, coated with catalysts, and assembly members for easy assembly, allowing for the integration of multiple blocks into a large-scale catalytic converter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ceramic catalyst supports are used, then manufacturing precision and structural integrity are improved, but device complexity and assembly difficulty increase when scaling to large-capacity structures
Solution Approach 1:
The catalyst support is divided into multiple modular units, each comprising a frame structure with catalyst-coated panels. These standardized modules can be manufactured independently with high precision using conventional ceramic extrusion processes, then assembled into large-capacity structures through standardized connection interfaces, reducing overall assembly complexity while maintaining structural integrity
Solution Approach 2:
Connection structures serve as intermediaries between individual catalyst support modules, providing standardized interfaces that simplify assembly. These connection elements enable modular units to be joined together systematically, transforming the complex task of assembling large ceramic structures into a series of simple, repeatable connections
2Stability of the object's composition
If large-capacity catalytic converters are manufactured as single integrated structures, then structural stability is improved, but ease of manufacture and cost increase significantly
Solution Approach 1:
The large-capacity catalytic converter is segmented into multiple identical or standardized modules that can be manufactured using conventional extrusion processes. Each module maintains structural stability independently, and when assembled together, the modular structure achieves the required overall stability through standardized connection interfaces, dramatically reducing manufacturing complexity and cost
Solution Approach 2:
Multiple standardized catalyst support modules are merged together through connection structures to form the complete large-capacity catalytic converter. This combining approach allows each module to be manufactured efficiently using existing processes while the assembled structure achieves the required large capacity and structural stability
3Productivity
If catalyst support surface area is increased to handle large exhaust gas volumes, then exhaust gas purification efficiency is improved, but device complexity and assembly difficulty worsen
Solution Approach 1:
The large surface area required for exhaust gas purification is achieved by assembling multiple catalyst-coated panels into modular units. Each panel provides catalytic surface area, and the modular arrangement allows the total surface area to be scaled up systematically while maintaining manageable assembly complexity through standardized interfaces
Solution Approach 2:
The catalyst support structure utilizes three-dimensional spatial arrangement of modular panels to achieve large surface area within a compact volume. By stacking and arranging panels in multiple dimensions, the system maximizes catalytic surface area while maintaining a manageable external footprint and assembly complexity
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 solution simplifies the manufacturing process, reduces costs, and enables the creation of catalytic converters that meet international standards for exhaust gas purification in large vessels, facilitating the assembly of identical unit blocks into a large-scale structure.
Implementation Method 1
a catalyst coating layer such as alumina (for example, Al2O3, etc.) including precious metals is coated between the cell 4a and a cell passage barrier 2a
Implementation Method 2
an oxidation catalyst that oxides carbon monoxide (CO) and hydrocarbons (HC) from exhaust gas to be converted into carbon dioxide (CO2) and water (H2O)
Implementation Method 3
a reduction catalyst that reduces nitrogen compounds (NOx) into nitrogen (N2)
Data Source
AI summary
Provided is a large-capacity metal catalyst support and a catalytic converter using the same, in which a number of unit catalyst support blocks are changed in a form of being effectively assembled so as to be applied to a catalytic converter that is required for processing a large amount of exhaust gas such as large vessels or plants employing a number of large-scale internal combustion engines, or large food processing devices, to thus easily assemble the unit catalyst support blocks into a large-scale assembled structure. The catalyst support includes: a number of unit catalyst support blocks in which cell formation bodies formed of a number of hollow cells that are aligned in a longitudinal direction are accommodated and stacked in a polygonal supporter wherein a catalyst is coated on the surfaces of the hollow cells; and a number of assembly members each for fixing a pair of adjacent supports that mutually contact between the stacked unit catalyst support blocks.