Pleated Catalyst Module Reducing Pressure Drop
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Solution Overview
Problem
Catalytic reactors experience pressure drop due to structural impediments, leading to inefficiencies and parasitic power losses in industrial applications, particularly in denitrification processes where exhaust gas streams flow through modularized sections with traditional catalyst arrangements.
Innovation Solution
The use of structural catalyst bodies arranged in a pleated format, where pleat inlet faces form an angle with the module inlet face, creating fluid flow channels that reduce pressure drop while maintaining catalytic performance, employing a monolithic honeycomb structure or separated bodies with packing material, and optimizing parameters like pleat width, depth, and open area to manage secondary pressure losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional modularized catalyst sections are used with catalyst bodies arranged perpendicular to flow direction, then catalytic performance is maintained, but pressure drop increases due to structural impediments
Solution Approach 1:
The catalyst bodies are arranged at an angle (e.g., 45 degrees) relative to the direction of exhaust gas flow rather than perpendicular to it. This asymmetric arrangement reduces the structural impediment to flow while maintaining sufficient contact between the exhaust gas and catalytic surfaces, thereby reducing pressure drop without sacrificing catalytic performance.
Solution Approach 2:
The invention introduces a new spatial dimension by angling the catalyst body arrangement relative to the flow direction. This dimensional change allows the exhaust gas to flow more smoothly through the catalyst section, reducing turbulence and pressure drop, while the angled surfaces still provide adequate catalytic contact area.
2Ease of operation
If catalyst bodies are arranged perpendicular to flow direction, then catalytic contact area is maximized, but fluid flow resistance increases
Solution Approach 1:
By arranging catalyst bodies at an angle to the flow direction rather than perpendicular to it, the invention creates an asymmetric configuration that reduces flow resistance while preserving adequate catalytic contact area. The angled arrangement allows fluid to flow more easily past the catalyst bodies.
3Productivity
If sealing or packing materials are used between catalyst bodies for flow distribution, then flow distribution is improved, but device complexity and secondary pressure losses increase
Solution Approach 1:
The invention eliminates or removes the sealing or packing materials that were previously necessary between catalyst bodies. The angled arrangement of catalyst bodies inherently provides adequate flow distribution without requiring additional sealing components, thereby reducing device complexity and secondary pressure losses associated with these materials.
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 pleated arrangement of structural catalyst bodies effectively reduces pressure drop without compromising catalytic performance, allowing for efficient fluid flow and maintaining high catalytic activity in denitrification processes, applicable in industrial fluid treatment applications such as SCR reactors.
Implementation Method 1
The pleated arrangement of structural catalyst bodies effectively reduces pressure drop without compromising catalytic performance, allowing for efficient fluid flow
Implementation Method 2
Denitrification or selective catalytic reduction (SCR) technology is commonly applied to combustion-derived flue gases for removal of nitrogen oxides when passed through a catalytic reactor. Denitrification comprises the reaction of nitrogen oxide species in the gases, such as nitrogen oxide (NO) or nitrogen dioxide (NO2), with a nitrogen containing reductant, such as ammonia or urea
Data Source
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AI summary
In one aspect, catalyst modules and catalytic reactors are provided which, in some embodiments, mitigate inefficiencies and/or problems associated with fluid stream pressure drop A catalyst module comprises a layer of structural catalyst bodies arranged in a pleated format, the structural catalyst bodies forming pleat inlet faces and pleat outlet faces, wherein fluid flow channels defined by inner partition walls of the structural catalyst bodies extend from the pleat inlet faces to the pleat outlet faces. The pleat inlet faces form an angle (δ) with an inlet face of the module.