Segmented Bulk Material Holder for Thermal Expansion and Gas Flow
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Ammonia oxidation reactors face issues with bulk material compression and uneven thermal expansion leading to structural impairment, gas slippage, and reduced combustion efficiency due to the use of inflexible catalyst baskets and differential thermal expansion between the gas-permeable base plate and side walls, necessitating a stable and flexible design.
Innovation Solution
A holding device comprising an outer wall, gas-permeable base plate, rigid separating elements, and flexible support elements that allow for modular segmentation and stabilization of bulk materials, enabling variable design and improved gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a rigid catalyst basket is used to provide structural stability, then the basket maintains its shape, but thermal expansion causes differential movement between the base plate and side walls leading to gaps and bulk material structural impairment
Solution Approach 1:
The catalyst basket is divided into multiple rigid modules that can move independently relative to each other. Each module is connected through flexible joints, allowing differential thermal expansion between adjacent modules while maintaining overall structural integrity. This segmentation prevents gap formation between the base plate and side walls during thermal cycling.
Solution Approach 2:
The catalyst basket transitions from a completely rigid structure to a dynamic structure with flexible joints and movable modules. The flexible connections allow the basket to adapt its shape during thermal expansion, preventing stress concentration and structural failure while maintaining stability during operation.
2Quantity of substance
If the bulk material is compressed and compacted by movements and vibrations, then the bulk material height reduces, but this compression leads to cracks in the catalyst meshes and loss of combustion efficiency
Solution Approach 1:
Flexible support elements are introduced between the bulk material and the rigid basket structure. These flexible elements absorb mechanical stresses and vibrations, preventing direct transmission of compressive forces to the catalyst meshes. The flexible support elements maintain bulk material density while preventing mesh cracking and structural damage.
3Device complexity
If a single uniform catalyst basket design is used, then the structure is simple, but it cannot accommodate different bulk materials with different catalytic activities in different segments
Solution Approach 1:
The catalyst basket is segmented into multiple independent modules that can be individually filled with different bulk materials. Each module can contain materials with different catalytic activities tailored to specific functional requirements. The modular design allows flexible configuration of different materials in different segments without increasing overall structural complexity.
Solution Approach 2:
Different segments of the catalyst basket are designed with localized specific properties. Each module can be optimized for particular catalytic functions, allowing different bulk materials with different activities to be placed in different segments. This local differentiation enables versatile material configuration while maintaining a relatively simple overall basket structure.
4Ease of manufacture
If the gas-permeable base plate and side walls are made as a single rigid unit, then manufacturing is simple, but differential thermal expansion creates gaps and troughs in the bulk material
Solution Approach 1:
The base plate and side walls are segmented into separate components with flexible connections. This allows each component to expand and contract independently during thermal cycling, preventing differential expansion stresses. The segmented design maintains bulk material structure stability while remaining relatively simple to manufacture through modular assembly.
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 device stabilizes bulk materials under thermal loads, reduces movement, and optimizes gas flow and catalytic activity, enhancing combustion efficiency and preventing structural damage.
Implementation Method 1
at least one flexible and gas-permeable support element
Implementation Method 2
gas-permeable base plate
Data Source
Figure 1A~1B
Figure 2A~2F
AI summary
The present invention relates to a holding device for bulk materials, which is particularly suitable for use in ammonia oxidation reactors, and to a reactor comprising such a holding device. The invention also relates to a process for the catalytic oxidation of ammonia. The holding device has an outer wall, a gas-permeable base plate, at least one rigid separating element, and at least one flexible and gas-permeable support element. The outer wall delimits a volume which is closed off in one direction by the gas-permeable base plate, and the rigid separating element divides the volume into at least two main segments. The rigid separating element and the flexible and gas-permeable support element are arranged such that at least one of the main segments formed by the rigid separating element is divided into at least two subsegments.