Non-destructive Monolith Catalyst Testing via Sealed Pipe Segmentation
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Solution Overview
Problem
Existing methods for testing monolith catalysts are either prone to sampling errors and catalyst damage or are resource-intensive and inefficient due to the need for whole element testing, which requires extensive equipment and setup to accommodate various catalyst sizes and shapes.
Innovation Solution
A non-destructive monolith test system that allows for the testing of a small section of the catalyst element by directing a gas through pipes sealed against its surface, enabling multiple runs at different regions and varying gas compositions without removing the catalyst, thus eliminating sampling errors and equipment complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sample core is removed from the catalyst element for testing, then the catalyst activity can be measured, but sampling error and catalyst damage occur
Solution Approach 1:
The catalyst element is divided into multiple test sections that can be independently accessed through multiple openings in the support structure. This allows different regions of the catalyst to be tested separately without removing the entire element or compromising its overall integrity.
Solution Approach 2:
A support structure with openings and access channels serves as an intermediary mechanism that allows gas flow through specific sections of the catalyst element without requiring physical removal of the catalyst core. The support structure mediates between the testing requirement and the need to preserve the catalyst element.
2Measurement precision
If the entire catalyst element is tested, then sampling error is eliminated, but resource consumption and equipment complexity increase
Solution Approach 1:
The catalyst element is segmented into multiple testable sections through the support structure with multiple openings. This allows the system to test only the necessary portions of the catalyst rather than requiring the entire element to be installed and tested, reducing equipment complexity and resource consumption.
Solution Approach 2:
Instead of testing the entire catalyst element, the system performs partial testing by directing gas flow through specific sections accessed via the support structure openings. This partial action approach reduces the resources and equipment needed while still providing representative activity measurements.
3Adaptability or versatility
If multiple catalyst sizes and shapes are accommodated, then versatility is improved, but equipment complexity and setup time increase
Solution Approach 1:
The support structure with its standardized openings and access channels provides a universal platform that can accommodate catalyst elements of various sizes and shapes. The same basic structure serves multiple functions by allowing different configurations of gas flow paths and test sections, eliminating the need for specialized jigs and fixtures for each catalyst type.
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 approach provides efficient, non-destructive activity testing of monolithic catalysts, reducing damage and resource requirements, and allowing for accurate assessment of catalyst performance without the need for extensive jigs and fixtures to accommodate different sizes and shapes.
Implementation Method 1
testing the activity of a monolith catalyst... directing a gas through pipes having means of sealing them against the surface of the catalyst being tested
Data Source
AI summary
A system and method for non-destructive testing of a monolith catalyst element includes a a piping arrangement located above and below the element that seals against a portion of the element. A test fluid passes between the piping and therefore through the portion of the sealed catalyst section. Ports located in the piping allow for sampling of the fluid before and after the catalyst section. The catalyst element may then be repositioned for testing of a second portion of the element.