Regenerative Postcombustion Exhaust Gas Cleaning
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Solution Overview
Problem
Existing methods for cleaning exhaust gases with high concentrations of combustible components, such as those from hardening shops, face challenges including high energy consumption, large space requirements, and high maintenance costs, particularly when dealing with oxygen-free exhaust gases that contain up to 100% combustible components by volume.
Innovation Solution
The method involves using generative post-combustion, where exhaust gases are mixed with natural gas and combustion air in a burner to achieve stable combustion at high temperatures, with the heat energy from oxidation used to preheat the gases, followed by catalytic cleaning to ensure complete impurity conversion, and the system is designed for compactness and low energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal post-combustion (TNV) is used to clean exhaust gases, then complete conversion of hydrocarbons and reliable observation of pollutant limit values is achieved, but very high energy consumption occurs due to heating large amounts of diluted gas to high temperatures
Solution Approach 1:
The invention changes the temperature parameter from high (750-1000°C in TNV) to low (250-400°C in catalytic combustion), achieving complete hydrocarbon conversion through catalytic action rather than thermal energy, thus dramatically reducing energy consumption while maintaining reliable pollutant removal
Solution Approach 2:
The invention replaces the thermal/mechanical heating system with a catalytic chemical system, where a catalyst bed enables hydrocarbon oxidation at low temperatures without requiring high-energy heating equipment, thus eliminating the need to heat large volumes of diluted gas
2Reliability
If thermal post-combustion (TNV) is used to clean exhaust gases, then safe conversion of hydrocarbons is achieved, but manufacturing costs increase due to high-temperature-resistant materials and explosion-proof fittings
Solution Approach 1:
The invention changes the operating temperature from high (750-1000°C) to low (250-400°C), which eliminates the need for expensive high-temperature-resistant materials and explosion-proof fittings, significantly reducing manufacturing costs while maintaining safe hydrocarbon conversion through catalytic action
Solution Approach 2:
The catalyst bed serves as a cost-effective replacement for expensive high-temperature equipment; while catalysts may require periodic replacement, they eliminate the need for costly high-temperature-resistant steels and explosion-proof fittings, offering a more economical long-term solution
3Use of energy by stationary object
If regenerative afterburning (RNV) with heat recovery is used, then autothermal operation is achieved, but high equipment outlay and large space requirements occur
Solution Approach 1:
The invention achieves autothermal operation through the inherent energy content of the exhaust gases themselves, which provides sufficient heat for catalytic combustion without requiring external heat recovery equipment or regenerative systems, making the system self-sufficient and eliminating complex equipment outlay
Solution Approach 2:
The invention extracts and utilizes the energy content already present in the exhaust gases for catalytic combustion, eliminating the need for separate heat recovery and regenerative equipment, thus achieving autothermal operation with simpler, more compact equipment
4Reliability
If exhaust gases are diluted with air to less than 25% of lower explosion limit, then explosion protection regulations are complied with, but the amount of gas to be heated increases significantly
Solution Approach 1:
The invention changes the temperature parameter to low (250-400°C catalytic combustion), which allows direct combustion of undiluted or minimally diluted exhaust gases without creating explosive mixtures, thus eliminating the need to heat large volumes of diluted gas while maintaining explosion safety through controlled catalytic oxidation
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 allows for efficient and compact exhaust gas cleaning with minimal energy consumption and low maintenance, capable of handling high concentrations of combustible components, achieving around 98% impurity removal in the burner and complete conversion in the catalytic stage, with the ability to quickly start and operate independently of carbon monoxide concentrations.
Implementation Method 1
burned in a combustion chamber
Implementation Method 2
oxidation of the exhaust gases
Implementation Method 3
catalytic cleaning stage
Data Source
Figure 1
Figure 2
AI summary
The method involves supplying exhaust gases to be cleaned, and balancing pressure and quantity fluctuations in the exhaust gases. A gas flow of exhaust gases is mixed with another gas flow of natural gas in such a manner that the added quantity of natural gas is dependent of the content of the inflammable components in the exhaust gases and is sufficient to ensure a stable burn. The mixed gas flows and a third gas flow of combustion air are introduced into a burner (6) of a combustion chamber (7). An independent claim is included for a device for the execution of the method.