Porous Catalyst Assembly for Indirect Heating Heat Recovery
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Solution Overview
Problem
Current indirect heating systems in heavy industries suffer from significant heat loss due to the direct discharge of heated smoke, with existing solutions like silicon carbide inserts being expensive and ineffective in catalyzing smoke components.
Innovation Solution
An energy-saving assembly comprising porous elements with holes and spiral elements coated with an oxidation catalyst, which are integrated into the radiant tube to enhance convective heat transfer, catalyze residual methane and carbon monoxide, and increase turbulence in the smoke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If silicon carbide inserts are used to promote convective heat transfer, then tube-wall temperature increases by 5-30°C, but the inserts are expensive and do not catalyze smoke components
Solution Approach 1:
The patent combines the heat transfer function (porous structure) with the catalytic function (coating) into a single integrated assembly. The porous carrier provides both the physical structure for heat transfer and the surface for catalytic reactions, eliminating the need for separate inserts and achieving both temperature increase and smoke component catalysis simultaneously
Solution Approach 2:
The patent uses a composite structure consisting of a porous carrier material coated with catalytic substances. This composite approach allows the assembly to perform multiple functions: the porous structure facilitates heat transfer while the catalytic coating promotes chemical reactions in the smoke, resolving the contradiction between cost-effectiveness and functional performance
2Device complexity
If heated smoke is directly discharged, then the system is simple, but heat loss accounts for 44% with smoke contributing more than 25%
Solution Approach 1:
The patent converts the harmful hot smoke that causes heat loss into a beneficial resource by using the porous assembly to catalyze the smoke components. The catalytic reaction converts residual methane and carbon monoxide in the smoke into useful heat, transforming the waste heat loss problem into an energy recovery solution while maintaining relative system simplicity
3Temperature
If conventional plug-in tools are used, then heat transfer is improved, but they are expensive, have poor tolerance, and suffer from carbon deposits
Solution Approach 1:
The patent employs a porous carrier structure that provides high surface area for heat transfer and catalytic reactions. The porous structure facilitates better thermal contact with the smoke while the coated surface prevents carbon deposits and improves durability, resolving the issues of tolerance and reliability associated with conventional plug-in tools
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 assembly effectively increases the tube-wall temperature by 5-35°C, enhances heat transfer performance, and achieves energy savings by recycling heat from catalyzed smoke components.
Implementation Method 1
the porous carrier being coated by an oxidation catalyst having a chemical formula of Cu1-xMxOy, the M being a Ce or an Mn
Implementation Method 2
an oxidation catalyst having a chemical formula of Cu1-xMxOy
Implementation Method 3
With structural turbulence of the smoke promotes convective heat transfer in the radiant tube
Implementation Method 4
guide the smoke, and increase the turbulence
Implementation Method 5
the porous carrier having a plurality of holes penetrating individually the porous carrier
Data Source
AI summary
An energy-saving assembly for indirect heating systems includes a plurality of porous elements. Each porous element has a porous carrier which has multiple holes that go through the carrier. The porous carriers are arranged parallel to the axis of a radiant tube of the indirect heating system at a distance or adjacent and disposed of inside the radiant tube. The outer periphery of each porous element is at least partly adjacent to the inner wall of the radiant tube.