Stacked Strand Catalyst Structure for Low Pressure Drop
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Solution Overview
Problem
Current catalysts prepared through robocasting have high surface areas but suffer from high pressure drops across monolith bodies, leading to inefficient gas flow and mechanical instability, which limits their use in packed bed reactors.
Innovation Solution
A three-dimensional porous catalyst structure composed of stacked strands with specific layer patterns, including parallel strands arranged in groups with varying distances, allowing for multiple flow directions and reducing pressure drop while maintaining high surface area and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If robocasting is used to prepare catalyst structures, then high surface area is achieved, but pressure drop increases and mechanical stability decreases
Solution Approach 1:
The catalyst structure is segmented into multiple thin layers stacked together, where each layer contains parallel strands arranged in groups. This segmentation allows the structure to maintain high surface area while reducing the pressure drop across each individual layer, as the flow path is distributed across multiple layers rather than one thick structure.
Solution Approach 2:
The invention transitions from traditional single-block or monolithic catalyst structures to a three-dimensional stacked configuration. By arranging parallel strands in groups within layers and stacking multiple layers, the catalyst creates a multi-dimensional flow path that reduces pressure drop while maintaining high surface area contact between gas and catalyst.
2Productivity
If smaller catalyst extrudates are used to increase surface area, then mass transfer performance improves, but mechanical strength decreases
Solution Approach 1:
Multiple thin layers are merged into a single stacked structure that functions as one mechanical unit. The stacking and drying process creates strong inter-layer bonds, giving the overall structure the mechanical strength of a single robust piece while maintaining the mass transfer benefits of thin-layer geometry.
Solution Approach 2:
The binder is incorporated into the paste before extrusion and drying, creating preliminary mechanical bonds between strands and layers. This preliminary bonding during manufacturing ensures the structure has sufficient mechanical strength before being put into service, avoiding the need for post-assembly reinforcement.
3Stability of the object's composition
If high-temperature sintering is applied to robocasted structures, then mechanical stability improves, but catalyst properties deteriorate
Solution Approach 1:
The invention changes the binding mechanism from thermal sintering at high temperatures to chemical bonding at lower temperatures using reactive binders. This parameter change in the bonding process allows the catalyst structure to achieve mechanical stability without exposing the catalytically active metals to temperatures that would cause sintering and loss of dispersion.
Solution Approach 2:
A binder acts as an intermediary material that provides mechanical cohesion between catalyst particles and strands at low temperatures. The binder enables structural integrity without requiring high-temperature treatment, thereby protecting the catalyst properties while still achieving the necessary mechanical stability for reactor operation.
Data Source
AI summary
A three-dimensional porous catalyst, catalyst carrier or absorbent structure of stacked strands of catalyst, catalyst carrier or absorbent material, composed of layers of spaced-apart parallel strands, wherein parallel strands within a layer are arranged in groups of two or more closely spaced-apart, equidistant strands separated by a small distance, wherein the groups of equidistant strands are separated from adjacent strands or adjacent groups of strands by a larger distance.