Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J35/00—Catalysts, in general, characterised by their form or physical properties
  • B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
  • B01J35/56—Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
  • B01D53/34—Chemical or biological purification of waste gases
  • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
  • B01D53/86—Catalytic processes
  • B01D53/8671—Removing components of defined structure not provided for in B01D53/8603 - B01D53/8668
  • B01D53/8675—Ozone
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
  • B01D53/34—Chemical or biological purification of waste gases
  • B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
  • B01D53/86—Catalytic processes
  • B01D53/88—Handling or mounting catalysts
  • B01D53/885—Devices in general for catalytic purification of waste gases
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J15/00—Chemical processes in general for reacting gaseous media with non-particulate solids, e.g. sheet material; Apparatus specially adapted therefor
  • B01J15/005—Chemical processes in general for reacting gaseous media with non-particulate solids, e.g. sheet material; Apparatus specially adapted therefor in the presence of catalytically active bodies, e.g. porous plates
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
  • B64D13/00—Arrangements or adaptations of air-treatment apparatus for aircraft crew or passengers, or freight space
  • B64D13/06—Arrangements or adaptations of air-treatment apparatus for aircraft crew or passengers, or freight space the air being conditioned
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2235/00—Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2235/00—Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
  • B01J2235/30—Scanning electron microscopy; Transmission electron microscopy
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
  • B64D13/00—Arrangements or adaptations of air-treatment apparatus for aircraft crew or passengers, or freight space
  • B64D13/06—Arrangements or adaptations of air-treatment apparatus for aircraft crew or passengers, or freight space the air being conditioned
  • B64D2013/0603—Environmental Control Systems
  • B64D2013/0685—Environmental Control Systems with ozone control

Definitions

• the present invention relates generally to environmental control systems, and more particularly, to an environmental control system incorporating a catalytic reactor for the decomposition of ozone in air.
• the environmental control system of the present invention has particular application for use in conditioning the air supplied to a passenger cabin of an aircraft.
• the environmental control system of the present invention may also be used in conjunction with other transportation machines such as military tanks.
• Aircraft environmental control systems supply pressurized and conditioned air to the aircraft cabin.
• the temperature, pressure and relative humidity must be controlled to provide for the comfort of the flight crew and passengers within the aircraft.
• Modem commercial jet aircraft are typically designed for fuel-efficient operation at relatively high altitudes of 25,000 feet or more above sea level where the ozone content of the air is relatively high. Accordingly, during operation at high altitudes the air supplied to the aircraft cabin from the environmental control system may contain ozone at a level of 1 - 3 ppmv.
• the presence of ozone in the air within the aircraft cabin can cause lung and eye irritation, headaches, fatigue and/or breathing discomfort.
• catalytic converters, or reactors, of this type have found widespread use, they are subject to the following limitations.
• the washcoat is subject to attrition when exposed to continued vibration and thermal cycling, such as that which may be experienced when a converter is used in an aircraft application.
• the washcoat and the catalyst carried by the washcoat may be washed off of the ceramic monolithic support structure during routine maintenance cleaning.
• catalytic reactors of this type typically include a plurality of spaced flow channels which are formed in the support structure along an axialJy extending axis, and through which the ozone-containing air flows under laminar conditions.
• Catalytic reactors of this type are typically mass-transfer limited, i.e.
• the efficiency of the reactor may be limited by the ability of the ozone molecule to diffuse to the surface of the catalyst. This requires laminar-flow reactors to be much larger, and consequently heavier, than those which may employ turbulent flow of the ozone-containing air through the reactor.
• the catalytic coating 58 is of the type described previously and is therefore subject to attrition when exposed to continued vibration and thermal cycling, such as that which may be experienced in an aircraft environment.
• Co-pending and commonly assigned U.S. Patent Applications 08/271.922 and 08/494,656 each disclose improved catalytic ozone converters of compact size and lightweight construction.
• Each of the co-pending applications discloses an aluminum or aluminum alloy support structure which comprises one or more fin elements disposed within a converter housing.
• Each of the fin elements includes a plurality of fins arranged in an axial succession of off-set fin rows between the inlet and outlet ends of the housing.
• the configuration of the fin elements results in a relatively high mass transfer between the ozone-containing air and the ozone carried by the fin elements for purposes of ozone decomposition.
• the fin elements have an integral anodized surface layer at least two microns thick, with the catalyst disposed on and within the anodized surface layer.
• one or more Group VIII noble metals and optionally base metals from Groups V ⁇ , IIIA. and VIIA are disposed on and within the anodized surface layer of the fin elements
• silver is disposed on and within the anodized surface layer of the fin elements, with this embodiment being preferred for relatively low temperature applicauons
• the catalytic converter disclosed in each of the referenced co-pending applications represent a significant improvement over the then-existing prior art since the integral anodized surface layer is not subject to attrition, unlike washcoats of p ⁇ or ceramic monolithic converters, and the turbulent flow and resulting h gh mass transfer rate promoted bv the fin element configuration (due to the tortuous paths created by the off-set fin rows), permits the converter to be more compact than p ⁇ or designs
• the compactness of the disclosed converters, coupled with the use of aluminum or aluminum alloy supports results in a lighter converter as compared to those employing ceramic monoliths
• the compactness of the disclosed converters, coupled with the use of aluminum or aluminum alloy supports
• the environmental control system comp ⁇ ses a catalytic reactor effective for decomposing at least a portion of the ozone present m the heated, ozone-containing airstream
• the catalytic reactor comp ⁇ ses a metallic housing having an inlet portion effective for receiving the heated, ozone-containing airstream an outlet portion effe ⁇ ive for discharging the airstream from the rea ⁇ or, and a generally cylind ⁇ cal portion disposed axially between and connected to the inlet and outlet portions
• the catalytic reactor further comp ⁇ ses a thermally compliant core structure constructed from a catalytically-active metal alloy, and the thermally compliant core structure is disposed within and connected to the generally cylindrical portion of the housing.
• the catalytically-reactive metal alloy is effective
• the thermally compliant core structure comp ⁇ ses a plurality of fin assemblies, with each of the fin assemblies being configured as an annular ⁇ ng
• the core structure may comp ⁇ se a single fin assembly wrapped upon itself in a spiral configuration
• the fin assemblies are generally concent ⁇ cally disposed relative to one another about an axially extending centerline axis of the catalytic reactor
• Each of the fin assemblies is brazed to radially adjacent ones of the fin assemblies so as to prevent nesting between radially adjacent pairs of the fin assemblies
• Each of the fin assemblies includes a plurality of fins which are arranged in an axial succession of rows of fins, with each of the rows of fins defining a plurality of axially extending flow channels.
• the fins and the flow channels of each of the rows of the fins are circumferentialiy off-set relative to the fins and the flow channels, respectively, of axially adjacent ones of the rows of the corresponding one of the fin assemblies so as to define a plurality of tortuous flowpaths through the flow channels of each of the fin assemblies for the flow of the heated, ozone-containing airstream through the thermally compliant core structure.
• the catalytically-a ⁇ ive metal alloy comprises a silver- containing metal alloy, and may have a composition including but not limited to silver and copper. Even more particularly, the cataiytically-a ⁇ ive metal alloy may have a composition comprising, on a weight basis, about 55% silver, about 39% copper, about 5% zinc and about 1% nickel.
• the catalytically-active metal alloy may be thermally activated by heating the alloy to a temperature ranging from about 300°F to about 420°F for a period of time ranging from about 30 minutes to about 60 minutes.
• the thermally compliant core structure of the catalytic reactor may be brazed to the generally cylindrical portion of the housing.
• the environmental control system may include a first heat exchanger having an inlet and an outlet for the flow of the airstream therethrough, with the first heat exchanger being adapted to receive a flow of cooling fluid in heat exchange, non-mixing relationship with the airstream so as to cool the airstream.
• the inlet of the first heat exchanger is in fluid communication with the outlet portion of the housing of the catalytic rea ⁇ or.
• the system may further include a compressor having an inlet in fluid communication with the outlet of the first heat exchanger and an outlet for discharging the airstream therefrom, with the compressor being effective for compressing the airstream.
• the system may further include a second heat exchanger having an inlet and an outlet for the flow of the airstream therethrough, with the inlet of the second heat exchanger being in fluid communication with the outlet of the compressor and with the second heat exchanger being adapted to receive a flow of cooling fluid in heat exchange, non-mixing relationship with the airstream so as to provide cooling to the airstream.
• the system may further include a turbine rotatably coupled to the compressor, with the turbine having an inlet in fluid communication with the outlet of the second heat exchanger and an outlet for discharging the airstream therefrom. The turbine is effe ⁇ ive for expanding and further cooling the airstream.
• the system may further include a third heat exchanger disposed upstream of the catalytic reactor, with the third heat exchanger having an inlet for receiving the heated, ozone-containing airstream and an outlet in fluid communication with the inlet portion of the housing of the catalytic reactor.
• the third heat exchanger is adapted to receive a flow of cooling fluid in heat exchange, non-mixing relationship with the airstream so as to cool the airstream.
• the system may further include a means for mixing the cooled airstream discharging from the turbine with a relative warmer airstream so as to produce a mixed airstream having a temperature which is higher than a temperature of the cooled airstream, prior to supplying the mixed airstream to the habitable space of the machine.
• an alternative to p ⁇ or environmental control systems is accomplished by providing a method for conditioning the heated, ozone-containing airstream prior to delivering the airstream to a habitable space within the machine.
• the method comprises the step of constructing a catalytic reactor having a housing and a thermally compliant core structure including a plurality of fin assemblies.
• the step of constructing comprises the steps of: manufacturing the fin assemblies from a single, catalytically-active metal alloy; configuring each of the fin assemblies as an annular ring; disposing the fin assemblies in generally concentric relationship with one another within a generally cylindrical portion of the housing; inserting braze foil between radially adjacent ones of the fin assemblies and between a radially outermost one of the fin assemblies and the housing; and brazing the fin assemblies to one another so as to prevent nesting between radially adjacent pairs of the fin assemblies and brazing the radially outermost fin assembly to the housing.
• the method further comp ⁇ ses the step of flowing the heated, ozone-containing airstream through the thermally compliant core structure of the catalytic reactor so that at least a portion of the airstream is in direct contact with the catalytically-active metal alloy
• the method may further comprise the step of thermally activating the catalytically-a ⁇ ive metal alloy, with the activating step comp ⁇ sing the step of heating the catalytically-a ⁇ ive metal alloy to a temperature rangmg from about 300°F to about 420°F for a period of time rangmg from about 30 minutes to about 60 minutes
• the catalytically-active metal alloy may be as desc ⁇ bed with respect to the first aspect of the invention.
• the method may further include the step of configuring each of the fin assemblies of the core stru ⁇ ure so as to define a plurality of tortuous flowpaths for the flow of the heated, ozone-containing airstream through the core structure.
• the method may further comp ⁇ se the step of cooling the airstream after the airstream discharges from the catalytic reactor, with the step of cooling comprising the step of flowing the airstream through at least one heat exchanger after the airstream discharges from the catalytic rea ⁇ or.
• a main advantage of the apparatus and method of the present invention is the provision of an environmental control system which incorporates a light, compact and cost efficient catalytic reactor for the decomposition of ozone in air, with the core structure of the reactor being constructed from a catalytically-active metal alloy and the reactor being substantially mass-transfer limited.
• Fig. 1 is a fragmentary isometric view illustrating a fin assembly, which is incorporated in the catalytic rea ⁇ or of the present invention
• Fig. 2 is an elevational view taken along line 2-2 in Fig. 1;
• Fig. 3 is an ozone destruction curve for the catalytically-active metal alloy of the present invention and illustrates the effe ⁇ s of thermally activating the alloy;
• Fig. 4 is a se ⁇ es of graphs illustrating the effect of temperature on the surface composition of the catalytically-active metal alloy of the present invention
• Fig. 5 is a photo micro-graph of the surface of the catalytically-a ⁇ ive metal alloy of the present invention in an as-received condition
• Fig. 6 is a photo micro-graph of the surface of the catalytically-active metal alloy of the present invention after thermal activation
• Fig. 7 is an ozone destruction graph illustrating the ability of the catalytically- active metal alloy of the present invention to recover after temporary exposure to a sulfur dioxide contaminated, ozone-containing feed air;
• Fig. 8 is a schematic view illustrating the environmental control system of the present invention.
• Fig. 9 is a perspective view illustrating the catalytic rea ⁇ or included in the environmental control system of the present invention.
• Fig. 10 is a cross-sectional view taken along line 10-10 in Fig. 9;
• Fig. 11 is an enlarged view of a portion of Fig. 10 illustrating the brazing of radially adjacent fin assemblies of one embodiment of the catalytic reactor of the present invention;
• Fig 12 is a cross-sectional vtew. similar to Fig 10. illustrating the catalytic reactor according to an alternative embodiment of the present invention
• Fig. 8 is a schematic view illustrating an environmental control system 50 according to a preferred embodiment of the present invention
• system 50 is used m an aircraft application
• the aircraft may include a plurality of engines, one of which is indicated schematically at 52
• the engme 52 receives ambient air 54 and processes the air 54 in a conventional manner for the purpose of producing propulsive power for propelling the aircraft
• the environmental control system 50 receives the heated, ozone- containing airstream, indicated by flow arrows 16 in Figs 1 and 9, via conduit 56
• the airstream 16 is supplied from a compressor stage, indicated at 58, of engine 52
• the airstream 16 may be provided from other sources such as ram air and/or a combination of compressor bleed air from engine 52 and ram air
• the heated, ozone contaimng airstream 16 is supplied via conduit 56 to a first inlet 60 of a heat exchanger 62 of system 50
• Heat exchanger 62 may comp ⁇ se a pre- cooler mounted to engme 52 and may be optionally omitted from system 50
• Heat exchanger 62 includes a first outlet 64 effective for discharging the airstream 16 from heat exchanger 62
• Heat exchanger 62 is also adapted to receive a flow of a cooling fluid, indicated by flow arrows 66, in heat exchange, non-mixing relationship with the airstream 16 so as to cool the airstream 16
• the cooling fluid 66 may comp ⁇ se ambient air, or alternatively air supplied from engme 52 at a lower temperature than airstream 16, such as fan discharge air or air from a lower compressor stage of engme 52
• the cooling fluid 66 is supplied to a second inlet 68 of heat exchanger 62 and discharges from heat exchanger 62 via a second outlet 70
• the first outlet 64 of heat exchanger 62 is
• System 50 further includes a rotatable compressor 92 having an inlet 94 which is in fluid communication with the first outlet 84 of heat exchanger 80, via a conduit 96
• Compressor 92 is rotatably coupled to a turbine 98 via shaft 100.
• Compressor 92 is effective for compressing the airstream 16, which discharges compressor 92 via an outlet 102.
• the airstream 16 is then supplied to a first inlet 104 of a heat exchanger 106, via a conduit 108.
• Heat exchanger 106 further includes a first outlet 110, effective for discharging airstream 16 from heat exchanger 106.
• Heat exchanger 106 is also adapted to receive a flow of cooling fluid, indicated by flow arrows 112, in heat exchange, non-mixing relationship with the airstream 16 so as to provide cooling to the airstream 16. Accordingly, heat exchanger 106 is effe ⁇ ive for off-setting at least a portion of the temperature rise caused by the compression of the airstream 16 within compressor 92.
• the cooling fluid 1 12 is supplied to a second inlet 114 of heat exchanger 106 and discharges from heat exchanger 106 through a second outlet 116 Cooling fluid 1 12 may be provided from the sources discussed previously in conjunction with cooling fluids 66 and 86, and may be provided from either common or different sources as those used to supply cooling fluids 66 and 86.
• Airstream 16 After discharging from outlet 110 of heat exchanger 106, airstream 16 is supplied to an inlet 1 18 of turbine 98 via a conduit 120. Turbine 98 is effective for expanding the airstream 16 and accordingly, for further cooling the airstream 16 Airstream 16 provides the motive force for rotating turbine 98, which in turn d ⁇ ves compressor 92 via shaft 100 The airstream 16 which has been cooled and has an ozone content within acceptable levels, discharges from turbine 98 through an outlet 122 and is supplied to a conditioner sub-assembly 124, which functions in a subsequently desc ⁇ bed manner, via a conduit 126. The airstream 16 is then supplied from the conditioner sub-assembly 124 to a habitable space 127, comprising a passenger compartment of the aircraft in the illustrative embodiment shown in Fig. 8, via a conduit 129
• the temperature of the airstream 16 may be below ambient temperature as airstream 16 discharges from the outlet 122 of turbine 98 such that any water vapor present in airstream 16 may be condensed into liquid water.
• the environmental control system 50 includes a means for mixing the cooled airstream 16 discharging from turbine 98 with a relatively warmer airstream prior to supplying the resultant mixed airstream to the habitable space 127.
• the means for mixing the cooled airstream 16 with a relatively warmer airstream includes a control valve 128 and conduits 130 and 132.
• a portion of the airstream 16 discharging from the catalytic rea ⁇ or 74 is routed through conduits 82 and 130 to an inlet of control valve 128, which establishes the desired flow rate of this airstream and is then supplied to conduit 126 via conduit 132 with this heated airstream mixing with the cooled airstream 16 so as to produce a mixed airstream having a temperature which is greater than the temperature of the cooled airstream 16 as it discharges from the outlet 122 of turbine 98.
• the mixed airstream is then supplied to the conditioner sub-assembly 124. Accordingly, by setting control valve 128 to a predetermined position, the temperature of the mixed airstream supplied to the conditioner sub-assembly 124 may be such that ice formation is prevented.
• the conditioner sub-assembly 124 comprises a condenser (not shown), an air/water separator (not shown) and a re-heater (not shown).
• the conditioner sub- assembly 124 is effective for separating any water contained within the mixed airstream prior to delivering the mixed airstream to the habitable space 127 and is further effective for increasing the temperature of the mixed airstream to an acceptable level p ⁇ or to delive ⁇ ng the mixed airstream to the habitable space 127 of the aircraft
• the specific construction of the catalytic reactor 74 according to a first preferred embodiment of the present invention is illustrated in Figs. 1, 2 and 9-11
• the inlet portion 72 of housing 73 includes a flanged, upstream end 134 which is attached to a flanged downstream end of conduit 77 via a pair of clamps 136 (one shown in Fig. 9)
• the outlet portion 76 of housmg 73 includes a flanged, downstream end 138 which is attached to a flanged upstream end of conduit 82 via a pair of clamps 140 (one shown in Fig 9)
• inlet portion 72 and outlet portion 76 of housmg 73 may be attached to conduits 77 and 82.
• housing 73 is preferably made of stainless steel
• housing 73 may be made of other metals such as aluminum, aluminum alloys, titamum and titanium alloys
• the core structure 10 is directly attached, by brazing, to the stainless steel housing 73 as subsequently discussed in greater detail.
• reactor 74 includes an intermediate ⁇ ng (not shown) made of stainless steel which is brazed to the core structure 10
• the intermediate ⁇ ng may be directly attached to housmg 73 by conventional means such as ⁇ vets, or alternatively the intermediate ring may be attached to housmg 73 with a resilient mount structure (not shown) which accommodates differential thermal growth between the housing 73 and the intermediate ⁇ ng.
• the resilient mount structure may include one or more sp ⁇ ngs and may be made of an elastome ⁇ c mate ⁇ al
• the inlet portion 72 of housing 73 comp ⁇ ses a diffuser which increases m diameter from a location ust aft of the flanged upstream end 134 to a downstream end which ts connected to the cylind ⁇ cal portion 75 of housmg 73 As shown m Fig.
• the inlet portion, or diffuser 72 merges smoothly with the cylindrical portion 75 of housing 73
• the inlet portion, or diffuser 72 is effective for reducing the velocity and increasing the sauc pressure of airstream 16
• This static pressure recovery may be important m the overall operation of the environmental control system 50 in certain applications since it is advantageous to limit the pressure drop through system 50 so as to avoid excessive use of power by engine 52 to provide the required airflow to the habitable space 127
• the core structure 10 of the catalytic rea ⁇ or 74 includes at least one fin assembly 12. with a portion of a single fin assembly 12 being illustrated in Figs. 1 and 2
• Each of the fin assemblies 12 of core structure 10 is constructed, or fab ⁇ cated from a catalytically-active metal alloy which is effective for decomposing ozone in the airstream 16, which comp ⁇ ses a central feature of the present invention
• the specific composition of the catalytically-active metal alloy is subsequently discussed in further detail.
• the core structure 10 comprises a plurality of the fin assemblies 12, with each of the fin assemblies 12 being configured as an annular ring.
• the fin assemblies 12 are generally concent ⁇ caliy disposed relative to one another about an axially extending centerline axis 142 (shown m Fig. 9) of reactor 74 Due to the physical limitations of configu ⁇ ng the fin assemblies 12 as annular ⁇ ngs, the center of the space defined by the housing 73 may be occupied by a small diameter support tube 146 having a finned st ⁇ p 148 Alternatively, the support tube 146 may be capped at both ends. In another preferred embodiment, illustrated in Fig.
• the core structure 10 of the catalytic rea ⁇ or 74 comp ⁇ ses a single fin assembly 12 which is wrapped upon itself in a spiral, or generally helical configuration It is noted that the views of the fin assembly shown in Figs. 1 and 2 are p ⁇ or to the fin assembly being configured as shown in either Figs. 10 or 12
• Each of the fin assemblies 12 includes an inlet end 14 which is effective for receiving the flow of the ozone-containing airstream 16 and an outlet end 18 effective for discharging the airstream 16 from the core structure 10.
• Each of the fin assemblies 12 further includes a plurality of fins 20 which are arranged in an axial succession of rows 22 of the fins 20 between the inlet end 14 and the outlet end 18 of the corresponding fin assembly 12.
• Each of the fin assemblies 12 is made by shaping a substantially flat, relatively thin sheet of the catalytically-active metal alloy of the present invention by conventional means such as stamping so as to form the plurality of the fins 20.
• the number of the rows 22 of fins 20, which are arranged between the inlet end 14 and the outlet end 18 of each fin assembly 12, may vary with the particular application of the catalytic reactor 74 Three of the rows 22 of fins 20 are illustrated in Fig. 1 and designated as 22A, 22B, and 22C.
• Rows 22A and 22B are further illustrated in the elevation view shown in Fig. 2.
• Each of the rows 22 includes a plurality of the fins 20 and defines a plurality of axially extending flow channels 24
• Each of the fins 20 includes a leading edge 25.
• the fins 20 and the flow channels 24 of each of the rows 22 are off-set by a distance x (Fig. 2) relative to the fins 20 and the flow channels 24, respectively, of axially adjacent ones of the rows 22.
• the fins 20 of row 22B are off-set with respect to the fins 20 of rows 22 A and 22C.
• the off-set x corresponds to a circumferential off-set after the fin assemblies 12. or the single fin assembly 12, have been configured as shown in Figs. 10 and 12, respectively.
• each fin assembly 12 is configured so as to define a plurality of tortuous flowpaths through the axially extending flow channels 24, defined by each of the rows 22 of fins 20, for the flow of the heated, ozone-containing airstream 16 between the inlet end 14 and the outlet end 18 of the corresponding one of the fin assemblies 12.
• This may be illustrated with reference to Fig. 1, although it should be understood that in actual use the airstream 16 does not flow through the fin assemblies 12 until they have been configured either as shown in Fig. 10 or in Fig. 12.
• the airstream 16 initially flows through the flow channels 24 of row 22A, depicted in Fig.
• the use of the off-set rows 22 of fins 20 within fin assembly 12 results in a substantially turbulent flow of the ozone-containing airstream 16 between the inlet end 14 and the outlet end 18 of each fin assembly 12. Since airstream 16 is substantially turbulent a relatively high mass transfer is achieved between the ozone- containing airstream 16 and the subsequently described catalyst, from which each fin assembly 12 is constructed.
• the overall mass transfer between airstream 16 and the catalyst of reactor 74 is further enhanced by the subsequently described methods of brazing radially adjacent ones of fin assemblies 12 to one another, or brazing radially adjacent spirals of an individual fin assembly 12 to one another (depending upon the particular configuration of reactor 74), as subsequently discussed in greater detail. As shown in Fig.
• each of the fins 20 has a generally re ⁇ anguiar cross-section in a preferred embodiment, as seen in an axial view, and includes a height H, an axial depth D. a thickness t, a pair of flats F, and an axial depth.
• Each fin 20 approximates a full sine-wave shape as illustrated in brackets in Fig. 2.
• the off-set x, as well as the overall size of the fins 20 may be varied to achieve the desired flow characteristics through each fin assembly 12 for a particular application.
• Each fin row 22 has a fin density which may also be varied with application. In the illustrative embodiments shown in Figs. 1, 2 and 9-12. each fin row 22 has a fin density of about 28 fins/in.
• each row 22 of fins 20 may vary with application
• each fin 20 preferably has a generally rectangular shape, the fins 20 may alternatively have other geomet ⁇ c shapes such as a generally triangular cross-section, or a generally trapezoidal cross-section
• each fin assembly 12 is configured as an annular ⁇ ng by conventional means such as rolling or forming, with the fins 20 of opposite ends of each fin assembly 12 being hooked together so as to maintain the desired configuration as an annular ⁇ ng.
• the radially outermost one of the fin assemblies 12 is brazed to the generally cylindrical portion 75 of housing 73 by inserting a thin braze foil (not shown) between the radially outer flat F of each of the fins 20 of the radially outermost fin assembly 12 and portion 75 of housing 73, and then heating the structure to the required braze temperature.
• each of the fin assemblies 12 is brazed to radially adjacent ones of the fin assemblies 12 This brazing is illustrated in Fig.
• FIG. 1 which is an enlarged view of a portion of Fig. 10 and illustrates a pair of radially adjacent fin assemblies, denoted as 12A and 12B in Fig 1 1
• a thin foil of braze alloy, indicated at 144, is placed between the radially outer fin assembly 12A and the radially inner fin assembly 12B
• each foil 144 of braze alloy is configured as a continuous concentric ring prior to brazing and is disposed between a radially adjacent pair of the fin assemblies 12.
• each foil 144 of braze alloy comprises a long, continuous ribbon which is wound up at the same time that the single fin assembly 12 is wrapped upon itself in a spiral configuration.
• the braze foil 144 is given one additional wrap to cover the radially outer spiral of the fin assembly 12 which provides the necessary braze alloy to attach the single fin assembly 12 to the generally cylindrical portion 75 of housing 73 or to an intermediate ring (not shown), depending upon the material of construction of housing 73. As shown in Figs. 10 and 1 1, the individual fins 20 of radially adjacent ones of the fin assemblies may randomly align, partially align or be misaligned. Placement of the braze foil 144 between each radially adjacent pair of fin assemblies 12 causes the aligned ones of the fins 20 of the adjacent pair of fin assemblies 12 to be brazed to one another, after exposure to the required brazing temperature.
• the lower flats F of the radially outer fin assembly 12A is brazed to aligned ones of the upper flats F of the radially inner fin assembly 12B.
• This brazing of radially adjacent ones of the fin assemblies 12 prevents nesting between the radially outer one and the radially inner one of each radially adjacent pair of fin assemblies 12 so as to maintain structural integrity of the core structure 10
• the radially adjacent spirals of the individual fin assembly 12 shown in Fig. 12. are brazed to one another. The method of brazing radially adjacent ones of the fin assemblies 12 shown in Fig.
• the use of the statistical brazing method of the present invention provides additional space for the fin assemblies 12, or the spirals of the individual fin assembly 12, within rea ⁇ or 74 as compared to an otherwise similar device using splitter plates or tube plates between the radially adjacent ones of the fin assemblies 12 or the radially adjacent spirals of the individual fin assembly 12
• each fin assembly 12 The quality and dist ⁇ bution of the braze conta ⁇ s within the core structure 10 of reactor 74 is enhanced by the mismatch in circumferential fin densities which occurs at the interface between each radially adjacent pair of fin assemblies 12 In the embodiment shown m Fig 10, the lateral width of each fin assembly 12. p ⁇ or to configuration as an annular ⁇ ng, is sized based on an average radius of the resultant annular ⁇ ng.
• the circumferential fin density as measured at the radially outermost portion of each fin assembly is less than the circumferential fin density as measured at the radially innermost portion of the fin assembly (corresponding to the radially inner ones of the flats F)
• the fin assemblies 12 are sized such that the circumferential fin density of the radially inner one of a pair of radially adjacent fin assemblies 12 is always less than the circumferential fin density of the radially outer one of the pair of fin assemblies 12 at the interface locations.
• the circumferential fin density of fin assembly 12B is less than the circumferential fin density of fin assembly 12 A as measured at location 148, further reducing the likelihood that radially adjacent fin assemblies 12 will nest with one another, thereby further enhancing the structural integ ⁇ ty of the core structure 10.
• splitter plates are typically inserted between the adjacent ones of fin assemblies within a stack.
• the resultant matrix in these conventional structures becomes very rigid and is incapable of being thermally compliant to the surrounding environment when in service.
• the core structure 10 of the present invention is thermally compliant which results from the ability of radially adjacent ones of the fin assemblies 12 shown in Fig.
• the catalytically-a ⁇ ive metal alloy used to manufacture the fin assemblies 12 comp ⁇ ses a silver-containing metal alloy and, in a preferred embodiment, has a composition including silver and copper as principle constituents
• An example of an alloy which the inventors have determined to be acceptable for use in the present invention has a composition comp ⁇ sing, on a weight basis, about 55% silver, about 39% copper, about 5% zinc and about 1% nickel. This composition corresponds to the following atomic ratios.
• the inventors have identified silver as the active catalyst and accordingly, the catalytically-active metal alloy of the present invention must comp ⁇ se a silver-containing metal alloy
• the catalytically-active metal alloy of the present invention must comp ⁇ se a silver-containing metal alloy
• the test results shown in Fig 3 corresponded to an ozone concentration of 2 36 ppmv and a flow rate of 1,000,000 GHSV (STP)
• STP 1,000,000 GHSV
• the alloy is extremely active for ozone decomposition, providing mass-transfer-limited performance at temperatures as low as 100°C. Accordingly, for low temperature applications, i.e. temperatures in which the ozone-containing airstream 16 is less than about 149°C the silver-containing metal alloy must be activated by calcining, or heating the alloy in air to a temperature ranging from about 149°C to about 216°C for a period of time ranging from about 30 minutes to about 60 minutes. For higher temperature applications, i.e. those in which the ozone-containing airstream 16 is at least 149°C the thermal activation step may be omitted.
• thermodynamic analysis of the surface composition of the fin assemblies 12 as a function of temperature was performed. Again, the composition of the silver- containing metal alloy corresponded to atomic ratios of: 30:36:4.5: 1.
• the results of the thermodynamic analysis illustrated graphically in Fig. 4, show that the surface composition of the silver-containing metal alloy (which is exposed to air) varies with temperature. At ambient temperature, the equilibrium surface composition is a mixture of CuO, Ag 2 O, ZnO and NiO. As shown in Fig. 4, this composition changes with temperature.
• a laboratory-scale reactor was assembled to include a se ⁇ ion of a fin assembly having 2 rows of fins, with each row of fins including 8 fins.
• Measured fin dimensions were approximately as follows: fin height (H in Fig 2) was 181 in (4 60 mm), fin thickness was 0 0036 in.
• the fin assembly section was constructed from a silver-containing metal alloy having a composition (D in Fig 1) comp ⁇ sing about 55% Ag, about 39% Cu, about 5% Zn and about 1% Ni
• the se ⁇ ion of the fin assembly was mounted in the laboratory-scale reactor and air contaimng 2 3 ppm by volume ozone was flowed through the fin assembly, so as to contact multiple surfaces of the silver-containing metal alloy, at 1 x 10 6 GHSV at STP and at the following five temperatures 50°C, 100°C, 150°C, 200°C, and 250°C
• the ozone conversion was measured, after 60 hours of operation usmg a PCI Ozone Monitor (Model LC) before and after the laboratory rea ⁇ or
• the results are presented in Table 1 Additionally, SEM-EDX analysis was performed on the surface of an as-received" sample of the silver-
• the "as-received" surface of the silver-contaimng metal alloy had a "white- copper” sheen
• the "as-received” metal alloy surface was relatively smooth in appearance with sub-micron size surface st ⁇ ations (possibly due to milling of the alloy du ⁇ ng manufacture)
• the activated silver-containing metal alloy surface had a dull gray appearance which was observed immediately after thermal activation As shown in Fig.
• the surface of the activated silver-containing metal alloy is roughened with particles which are about 1-10 microns in diameter
• the "particles” observed on the surface of the activated silver- containing metal alloy contained high concentrations of silver
• copper and oxygen were found in extremely low concentrations
• a laboratory reactor was assembled to a test section of a fin assembly, having the same number of rows and fins, and made from the same alloy, as that desc ⁇ bed in Example 1
• Durability testing was conducted to determine the ability of the silver- containing metal alloy to recover from a temporary poisoning with SO 2 , as follows Initially, a "clean" feed air contaimng 2 3 ppm by volume of ozone was flowed through the fin assembly at 1 x 10 6 GHSV at STP and at the following temperatures 100°C, 150°C, 200°C and 250°C After 20 hours of testing with the "clean" feed, 1 ppm by volume SO was added to the ozone-containing air for a period of 5 hours, after which the aforementioned "clean” feed was used for an additional 75 hours, at each temperature The ozone conversion was measured after I hour, 5 hours, 20 hours, and 60 hours of exposure to the ozone-containing air.
• Catalyst poisoning by surface adsorption of SO can be reversible depending on the strength of the catalyst-adsorbate bond.
• the rapid recovery in catalyst performance after SO 2 removal shown in Table 2 and Fig. 7 demonstrates that this poisoning was reversible over the temperature range tested. Accordingly, the temporary performance attenuation observed was due to "masking" of the catalyst sites by SO 2 .
• the use of the silver containing metal alloy in the catalytic reactor of the present invention provides a cost efficient, and relatively maintenance free, catalytic reactor for the decomposition of ozone in air.
• the present reactor is cost reduced relative to prior reactors, due to the elimination of process steps, since it is not necessary to apply a washcoat to, or anodize, a metallic substrate.
• the alloy itself comprises the active catalyst, the catalyst will not be removed during routine maintenance cleaning.
• the catalyst will not attrit when exposed to the vibration and thermal cycling which may be experienced when the rea ⁇ or is used in an aircraft application. Accordingly, the catalytic reactor 74 of the present invention has an increased service life relative to the known devices discussed in the Background section of this application.
• the use of the silver-containing metal alloy of the present invention in conjunction with the configuration of the core structure 10 which incorporates at least one fin assembly 12 and the statistical brazing methods of the present invention provides relatively high mass transfer between the ozone and the silver catalyst, and accordingly permits the use of a compact, lightweight reactor Additionally, the statistical brazing methods of the present invention enhance the mass transfer of the catalytic reactor 74 of the present invention due to the avoidance of the use of splitter plates or tube plates which also minimizes the weight of the catalytic reactor 74 of the present invention which is particularly important in aircraft applications. Furthermore, the statistical brazing methods of the present invention permit the core structure 10 of the catalytic reactor 74 to expand and contract with changes in environment temperature without the use of an intervening thermally compliant structure.

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• 1997
  • 1997-08-18 EP EP97938381A patent/EP0944426A1/de not_active Withdrawn
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