Multi-Segmented Ceramic Packing for Thermal Stress Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional ceramic structured packings face issues with thermal stress during firing and high-temperature applications, leading to breakage and increased production costs due to the need for expensive compounds like Aluminum Oxide to mitigate these stresses.
Innovation Solution
A process for creating Multi-Segmented Monoliths (MSMs) using ordinary clay or less expensive ceramic composites, where segments are attached with adhesives or mechanical means, such as dowel pins, to form a Compound MSM, reducing thermal stress and enhancing mechanical strength and thermal shock resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional ceramic structured packing is manufactured as a single elongated block, then the structure provides continuous flow passages, but thermal stress during firing causes breakage and reduces manufacturing yield
Solution Approach 1:
The monolith is divided into multiple segments that are attached together to form the complete structured packing. Each segment can be fired separately to avoid thermal stress-induced breakage, and the segments are then joined using adhesives or mechanical means to create the final continuous flow structure.
2Reliability
If expensive compounds like Aluminum Oxide are added to reduce thermal stress, then thermal shock resistance improves, but manufacturing cost increases significantly
Solution Approach 1:
By segmenting the monolith, the patent eliminates the need for expensive thermal stress-mitigating compounds. The segmentation allows ordinary clay to be used since each small segment experiences manageable thermal stress during firing, and the segments are joined after firing using cost-effective adhesives or mechanical attachment methods.
3Strength
If the monolith is segmented and attached after firing, then thermal stress resistance improves, but the structure introduces additional attachment components and assembly steps
Solution Approach 1:
The monolith is divided into segments that can be attached using simple adhesives or mechanical means such as dowel pins or tie-rods. The segments are designed with attachment features that minimize complexity, and the assembly process is streamlined to efficiently join the segments into the complete structured packing structure.
Data Source
AI summary
A multi-segmented monolith (MSM) which can be used as a structured packing in mass-transfer and catalytic operations is disclosed. The MSM comprises a series of longitudinally attached segments. The length of each segment is between 0.2 to 5 inches. Each segment has flow passages which extend from the inlet flow face to the outlet flow face. The segments are located such that the outlet of a flow passage on a segment is in flow communication with the inlet of a flow passage on an adjacent attached segment. The segments are attached to each other either in the green state or with an adhesive, such as sodium silicate. Alternately, the segments are attached to each other by a mechanical means, such as a tie-rod or a dowel pin. The MSM further includes a spacer means between adjacent segments. A plurality of MSMs are further assembled into a Compound MSM (CMSM).