Process Gas Preparation Device for Industrial Furnace
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Solution Overview
Problem
Existing industrial heat treating furnace systems face inefficiencies in process gas recycling and catalyst management, leading to high gas consumption and emissions, as well as potential catalyst clogging due to the lack of a shut-off valve and burn-out mechanism.
Innovation Solution
A process gas preparation device with a heatable, temperature-controlled catalyst, a compressor, and a control device that monitors and regulates the carbon level, pressure, and catalyst condition, including a shut-off valve to prevent spent gas flow and initiate targeted burn-out processes, along with mass flow controllers for precise gas supply and a cooler to prevent compressor damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If process gas is continuously flowed through the treatment chamber and discharged to a burn-off location, then the treatment chamber is adequately supplied with process gas, but gas consumption and emissions increase significantly
Solution Approach 1:
The patent implements a closed-loop system where spent process gas from the treatment chamber is recovered and regenerated in a preparation reactor rather than being discarded to a burn-off location. The gas is recycled back to the treatment chamber after regeneration, significantly reducing gas consumption and emissions while maintaining adequate process gas supply.
Solution Approach 2:
The system incorporates a feedback mechanism where the state of the process gas is monitored and the preparation reactor adjusts its operation accordingly. The control system regulates the regeneration process based on the actual condition of the spent gas, ensuring optimal regeneration efficiency and maintaining the required carbon content in the recycled gas.
2Loss of substance
If spent process gas is continuously recycled through a preparation reactor, then gas consumption is reduced, but catalyst clogging occurs due to lack of shut-off capability and burn-out mechanism
Solution Approach 1:
The patent implements periodic burn-out cycles for the catalyst in the preparation reactor. The control system periodically shuts off the spent gas flow using a shut-off valve and introduces air to the preparation reactor to burn out accumulated carbon deposits on the catalyst. This periodic maintenance action prevents catalyst clogging and maintains long-term catalyst functionality while enabling continuous gas recycling.
Solution Approach 2:
The system extracts the catalyst from the continuous gas flow path by providing it with a separate air supply line for burn-out operations. The shut-off valve isolates the catalyst from the spent gas flow during burn-out, allowing the catalyst to be cleaned independently without disrupting the overall gas recycling process.
3Productivity
If the preparation reactor operates continuously without shut-off valve control, then gas recycling is maintained, but precise control of gas supply and pressure cannot be achieved
Solution Approach 1:
The patent implements dynamic control of the preparation reactor through a shut-off valve that can adjust the flow of spent gas to the reactor. The control system can dynamically regulate the valve opening to control the amount of gas being recycled, adjusted based on the operational state and requirements of the treatment chamber. This enables precise control of gas supply and pressure while maintaining high recycling efficiency.
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
Optimizes process gas recycling, reduces gas consumption and emissions, ensures long-term catalyst efficiency by preventing clogging and maintaining optimal carbon levels, and allows for precise control of gas supply and pressure, enhancing the overall efficiency of the industrial heat treating process.
Implementation Method 1
a preparation reactor (6) which contains a heatable, temperature-controlled catalyst (7) and to which spent process gas from the industrial furnace (2; 23) can be conducted
Implementation Method 2
The feed line (8) incorporates a compressor (9), which is controlled by means of a control device (17) that also regulates process gas preparation and return
Implementation Method 3
a cooler to prevent compressor damage
Implementation Method 4
initiate targeted burn-out processes
Data Source
AI summary
A process gas preparation device for an industrial furnace system is disclosed. The gas preparation device includes a preparation reactor having a catalyst. A gas feed line and a gas return line are connected between the industrial furnace and the preparation reactor to form a closed loop. A compressor is situated upstream from the preparation reactor in the feed line. The preparation reactor is also connected with supply lines for hydrocarbon gas and air to be supplied to the preparation reactor. The process gas preparation device also includes a control device with which process gas preparation and return can be regulated and controlled. The gas feed line also has a shut-off valve. The control device can check the functional state of the catalyst by measuring the pressure differential across the catalyst and can initiate a burn-out process therein to clear clogging of the catalyst.