Resilient Moulding for Ceramic Catalyst Supports
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Solution Overview
Problem
Existing catalyst supports for industrial processes like steam reforming and direct-reduced iron production face limitations in achieving a balance between geometric surface area, strength, porosity, and cost-effectiveness, often resulting in reduced activity and increased costs due to mechanical handling and thermal cycling.
Innovation Solution
A moulding process using resiliently deformable silicone-based moulds with texturing and reservoir members to form ceramic catalyst supports, allowing for the creation of packing members with enhanced geometric surface area and strength while maintaining porosity, achieved through a multi-step deformation process and calcination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional extrusion or granulation methods are used to manufacture catalyst supports, then the manufacturing process is simple and cost-effective, but the geometric surface area is limited and porosity is poor
Solution Approach 1:
The mould is divided into a first mould part and a second mould part that can move relative to each other. The first mould part remains stationary while the second mould part moves from an open position to a closed position, allowing the liquid ceramic composition to be poured into open cavities and then enclosed to form green bodies with enhanced geometric surface area and controlled porosity.
2Ease of manufacture
If traditional extrusion or granulation methods are used to manufacture catalyst supports, then the manufacturing process is simple, but the porosity is poor
Solution Approach 1:
The second mould part is designed to be movable, transitioning from an open position where liquid ceramic composition can be poured into open cavities to a closed position that encloses the cavities. This dynamic approach allows controlled filling and enclosure to achieve desired porosity while maintaining manufacturing simplicity.
3Strength
If catalyst supports are made with high strength, then mechanical durability is improved, but geometric surface area and porosity are reduced
Solution Approach 1:
The invention changes the manufacturing parameters by using a movable mould part system that allows liquid ceramic composition to be poured into open cavities and then enclosed. This process enables the production of supports with optimized parameters achieving both high strength and enhanced geometric surface area, resolving the traditional trade-off between these properties.
4Strength
If catalyst supports are made with high strength, then mechanical durability is improved, but porosity is reduced
Solution Approach 1:
The movable mould part system enables control over the filling and enclosure process, allowing optimization of both strength and porosity parameters simultaneously. The liquid ceramic composition is poured into open cavities and then enclosed by moving the second mould part to a closed position, creating green bodies with balanced mechanical properties and porosity.
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 process enables the production of catalyst supports with improved geometric surface area, strength, and porosity, reducing scrap rates and operational costs, while maintaining high heat transfer and gas flow efficiency, suitable for surface-based catalytic reactions.
Implementation Method 1
the first and/or second mould parts are resiliently deformable and wherein the first part and/or the second part comprise a plurality of open mould cavities, wherein the first and second parts are operable to engage to form closed mould cavities
Data Source
AI summary
A mould for manufacturing a packing member from a liquid ceramic composition. The mould including a first part and a second part, in which the first and/or second mould parts are resiliently deformable and the first part and/or the second part include a plurality of open mould cavities. The first and second parts are operable to engage to form closed mould cavities, and the mould is operable to be moved from an open position in which the first and second parts are partially spaced by the deformation of a mould part and in which position mould cavities are open, to a partially closed position by reducing the deformation of the mould part and in which position some of the mould cavities are closed, and then to a closed position by further reducing the deformation of the mould part and in which position the first and second parts are engaged such that the mould cavities are closed.