Used Catalyst Gauze Pieces for Reliable Ignition
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Solution Overview
Problem
Metal catalyst gauze enhanced ignition startup problems, including difficulty in igniting reactants with new, contaminated, or damaged catalysts, result in significant production losses and yield impacts due to high activation energy requirements and contamination issues, despite existing techniques to enhance ignition processes.
Innovation Solution
Incorporating 0.25 to 1.5 wt.% of previously used, uncontaminated metal catalyst gauze pieces on a new metal catalyst gauze, such as platinum/rhodium, to reduce activation energy and promote reliable ignition at relatively low temperatures, without the need for expensive coatings or special conditioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If new metal catalyst gauze is used, then catalyst cost is reduced, but ignition reliability deteriorates due to high activation energy
Solution Approach 1:
The patent applies preliminary action by placing small pieces of previously used catalyst gauze on the new catalyst gauze before the ignition process. These pre-placed pieces serve as ignition nuclei that lower the activation energy barrier, enabling reliable ignition without requiring expensive platinum black coatings or extended conditioning periods. The used catalyst pieces are positioned in advance to facilitate immediate ignition when reactants are introduced.
2Reliability
If platinum black coating is applied to lower ignition temperature, then ignition reliability improves, but manufacturing cost increases significantly
Solution Approach 1:
The patent employs the principle of using cheap, disposable objects by replacing expensive platinum black coatings with small pieces of previously used catalyst gauze. These used pieces act as temporary ignition promoters that facilitate reliable light-off without requiring costly re-coating operations. The approach treats the ignition promotion function as a consumable role filled by discarded catalyst fragments rather than permanent surface modifications.
Solution Approach 2:
The patent applies parameter changes by altering the physical state and distribution of catalyst material. Instead of increasing platinum loading through coating, the invention changes the activation energy parameter by introducing used catalyst pieces with different surface properties. This parameter change enables ignition at lower temperatures without modifying the bulk catalyst composition or requiring expensive surface treatments.
3Reliability
If catalyst ignition is attempted multiple times, then ignition reliability may improve, but production loss increases due to reactor downtime
Solution Approach 1:
The patent applies preliminary action by pre-positioning ignition-promoting catalyst pieces before introducing reactants. This preliminary preparation ensures that ignition nuclei are already in place, eliminating the need for multiple ignition attempts and repeated reactor clearing operations. The pre-arranged catalyst pieces guarantee successful ignition on the first attempt, maximizing production volume by minimizing reactor downtime.
Solution Approach 2:
The patent employs self-service by using previously used catalyst pieces that inherently possess the necessary catalytic properties to promote ignition. These self-contained catalyst fragments require no additional treatment, coating, or activation steps - they simply need to be placed on the new gauze and will automatically facilitate ignition when exposed to reactants, eliminating the need for external intervention or repeated ignition attempts.
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
Enables rapid and reliable ignition of new, used, or contaminated metal catalyst gauzes, reducing reactor downtime and increasing yield by facilitating ignition within 15 minutes, similar to used gauzes with higher surface areas, while minimizing flared feed gases and avoiding repeated light-off failures.
Implementation Method 1
one or more pieces of previously used metal catalyst gauze... that reduce the activation energy for ignition of reactants at the surface of metal catalysts
Data Source
AI summary
The present invention provides materials for improving the ignition of gaseous reactants in metal catalyzed oxidation reactions comprising a metal catalyst gauze, preferably, a platinum/rhodium catalyst gauze, having in contact therewith, from 0.5 to 1.5 wt. %, based on the weight of the metal catalyst gauze, of one or more pieces of previously used metal catalyst gauze. Further, methods of making the metal catalyst materials comprise shaping the pieces of previously used metal catalyst gauze and placing them equidistant from each other in contact with or on the surface of the metal catalyst gauze. And methods of using the materials comprise feeding into the reactor a gas mixture of oxygen or air and one or more reactant gases, and igniting the gas mixture at the surface of one or more or all of the pieces of previously used metal catalyst.