US20060242951A1 - Refractory material retention device - Google Patents
Refractory material retention device Download PDFInfo
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- US20060242951A1 US20060242951A1 US11/117,573 US11757305A US2006242951A1 US 20060242951 A1 US20060242951 A1 US 20060242951A1 US 11757305 A US11757305 A US 11757305A US 2006242951 A1 US2006242951 A1 US 2006242951A1
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- Prior art keywords
- refractory material
- material body
- support layer
- section
- sectional area
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/08—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous
- F01N3/10—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust
- F01N3/24—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for rendering innocuous by thermal or catalytic conversion of noxious components of exhaust characterised by constructional aspects of converting apparatus
- F01N3/28—Construction of catalytic reactors
- F01N3/2839—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration
- F01N3/2842—Arrangements for mounting catalyst support in housing, e.g. with means for compensating thermal expansion or vibration specially adapted for monolithic supports, e.g. of honeycomb type
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
- F01N3/023—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles
- F01N3/025—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters using means for regenerating the filters, e.g. by burning trapped particles using fuel burner or by adding fuel to exhaust
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D14/00—Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
- F23D14/46—Details, e.g. noise reduction means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2240/00—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being
- F01N2240/14—Combination or association of two or more different exhaust treating devices, or of at least one such device with an auxiliary device, not covered by indexing codes F01N2230/00 or F01N2250/00, one of the devices being a fuel burner
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D2212/00—Burner material specifications
- F23D2212/10—Burner material specifications ceramic
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23D—BURNERS
- F23D2213/00—Burner manufacture specifications
Definitions
- This disclosure pertains generally to refractory materials, and more particularly, to systems and methods for securing high-temperature refractory materials within an exhaust system.
- Some exhaust system components are subjected to extreme environmental conditions, including high temperatures. Consequently, a variety of materials have been developed to withstand these high-temperatures, while performing important functions within the exhaust system. Such materials include a number of different ceramics and composite foams, which may form important components of exhaust system combustion burners.
- ceramic and composite foams may be particularly well-suited for some conditions, including high temperatures, such foams have some disadvantages.
- some ceramic foams may be brittle, and over time, the brittle foams may be damaged by repeated mechanical stress.
- the high temperature of the foam may damage adjacent structures, including foam retention devices, which may be less resistant to thermal damage. Damage to either the foam or adjacent foam retention devices may cause foam loosening and ultimate device failure. Therefore, improved foam retention devices are needed to prevent damage to the brittle foams and to withstand operational environmental conditions.
- the '483 patent describes a honeycomb ceramic catalyst support.
- the support includes a substrate skin surrounding a catalyst core.
- the substrate skin is surrounded by a ceramic barrier coating.
- the catalyst support of the '483 patent may provide suitable support for some materials
- the support of the '483 patent has several disadvantages.
- the support of the '483 patent may not adequately protect materials that may be disposed between the catalyst and the exhaust system enclosures. As a result, these materials may degrade when exposed to high temperatures, as produced by exhaust system combustion burners.
- the support of the '483 patent may not provide adequate protection to brittle foam materials, as used in some exhaust system components.
- the present disclosure is directed to overcoming one or more of the disadvantages of the prior art material retention devices.
- the system may include a tubular enclosure having a first section and a second section, wherein the first section has an internal cross-sectional area that is less than an internal cross-sectional area of the second section.
- a refractory material body may be disposed within the tubular enclosure second section.
- a first support layer may be disposed on a surface of the refractory material body, and at least one outer support layer may be disposed between the refractory material body and a wall of the tubular enclosure second section.
- the first support layer may form an insulating barrier between the refractory material body and the outer support layer.
- a cross-sectional area of the combined refractory material body and first support layer may be at least as large as the internal cross-sectional area of the tubular enclosure first section.
- a second aspect of the present disclosure includes a method for securing a refractory material within an exhaust system burner unit.
- the method may include selecting a refractory material body, applying a first support layer to a surface of the refractory material body, applying at least one outer support layer to a surface of the first support layer, and positioning the refractory material body, first support layer, and at least one outer support layer within a burner tubular enclosure.
- the tubular enclosure may have a first section which has a first internal cross-sectional area and a second section which has a second internal cross-sectional area, wherein the first internal cross-sectional area is less than the second internal cross-sectional area.
- a cross-sectional area of the combined refractory material body and first support layer is at least as large as the first internal cross-sectional area.
- a third aspect of the present disclosure includes a work machine.
- the work machine may include an engine, an exhaust system configured to receive an exhaust gas stream produced by the engine, and a burner unit configured to heat the exhaust gas stream.
- the burner unit may include a tubular enclosure having a first section and a second section, wherein the first section has an internal cross-sectional area that is less than an internal cross-sectional area of the second section.
- a refractory material body may be disposed within the tubular enclosure second section.
- a first support layer may be disposed on a surface of the refractory material body, and at least one outer support layer may be disposed between the refractory material body and a wall of the tubular enclosure second section.
- the first support layer may form an insulating barrier between the refractory material body and the outer support layer.
- a cross-sectional area of the combined refractory material body and first support layer may be at least as large as the internal cross-sectional area of the tubular enclosure first section.
- a fourth aspect of the present disclosure includes a work machine.
- the work machine may include an engine, an exhaust system configured to receive an exhaust gas stream produced by the engine, and a burner unit configured to heat the exhaust gas stream.
- the burner unit may include a tubular enclosure having a first section and a second section, and a refractory material body may be disposed within the tubular enclosure second section.
- a first support layer may be disposed on a surface of the refractory material body, and at least one outer support layer may be disposed between the refractory material body and a wall of the tubular enclosure second section.
- the outer support layer may be insulated from the refractory material body and an interior of the tubular enclosure.
- FIG. 1 illustrates a work machine according to an exemplary disclosed embodiment.
- FIG. 2 illustrates an engine and exhaust system including a combustion burner system, according to an exemplary disclosed embodiment.
- FIG. 3 provides a side view of a refractory material retention system, according to an exemplary disclosed embodiment.
- FIG. 4 provides a side view of a refractory material retention system, according to an exemplary disclosed embodiment.
- FIG. 5 illustrates an exploded view of the refractory material retention system, according to the embodiment of FIG. 4 .
- FIG. 6 illustrates a refractory material retention system, according to another exemplary disclosed embodiment.
- FIG. 7 provides a side view of a refractory material retention system, according to another exemplary disclosed embodiment.
- FIG. 1 illustrates a work machine 10 of the present disclosure.
- work machine 10 includes an off-highway truck.
- work machine 10 may include any work machine that may include an exhaust system refractory material.
- Such work machines may include, for example, on-highway trucks, ocean vessels, excavators, generator sets, oil drilling equipment, etc.
- Work machine 10 may include an engine 12 , which may supply an exhaust gas stream 14 to an exhaust system 16 (as shown in FIG. 2 ).
- FIG. 2 illustrates engine 12 and exhaust system 16 , according to an exemplary disclosed embodiment.
- Exhaust system 16 may include an exhaust passage 18 , which may be configured to carry exhaust gas stream 14 produced by engine 12 .
- Exhaust system 16 may also include a number of catalysts, filters, and/or burners.
- exhaust system 16 includes a first catalyst unit 20 , a diesel particulate filter (DPF) 22 , and a second catalyst unit 24 .
- Exhaust system 16 may further include one or more burner units 26 , which may be configured to heat exhaust gas stream 14 and/or other components of exhaust system 16 , such as DPF 22 or second catalyst unit 24 within exhaust passage.
- DPF diesel particulate filter
- Catalyst units 20 , 24 and DPF 22 may include any suitable catalyst and/or filter type.
- catalyst units 20 , 24 may include, for example, oxidation catalysts, three-way catalysts, selective catalytic reduction system catalysts, and/or any other suitable catalyst.
- exhaust system 16 may include additional catalysts, filters, additive supply devices, and/or other suitable exhaust system component, such as fuel-injectors, systems for adding oxidants or reductants, air-intake valves, exhaust valves, temperature sensors, gas sensors, forced-induction systems, and/or any other suitable exhaust system component.
- Burner unit 26 may include a number of suitable burner unit types.
- burner unit 26 may include a number of different fuel combustors, which may be configured to heat exhaust gas stream 14 to a selected temperature.
- Burner unit 26 may produce heat by combustion of a number of different fuels, such as diesel fuel or gasoline.
- the fuel may be supplied to burner unit 26 using a number of suitable fuel-supply systems including, for example, various valves, injectors, atomizers, and/or any other suitable fuel-supply system.
- the fuel may be mixed with air provided by any suitable air supply system to facilitate combustion.
- Burner unit 26 may be configured to heat exhaust gas stream 14 and one or more components of exhaust system 16 to a selected temperature. The desired temperature may be selected to facilitate one or more exhaust system functions. Such exhaust system functions may include, for example, control of one or more catalyst operations or regeneration of one or more exhaust system components. In one embodiment, burner unit 26 may be configured to heat DPF 22 and/or one or more downstream catalysts 24 to facilitate regeneration of DPF 22 and/or one or more downstream catalysts 24 . For example, in one embodiment, burner unit 26 may be configured to heat DPF 22 to a temperature that may facilitate removal of soot and/or other deposits from DPF 22 .
- burner unit 26 may be configured to heat DPF 22 and/or other components of exhaust system 16 to temperatures up to 650° Celsius, to temperatures up to 900° Celsius, to temperatures up to 1200° Celsius, to temperatures up to 1500° Celsius, or to temperatures up to 1700° Celsius.
- burner unit 26 may include a tubular member 28 , which may be configured to supply heat produced within burner unit 26 to exhaust passage 18 . Further, burner unit 26 may include a refractory material unit 30 . Changes in operating conditions of engine 12 may cause variations in the pressure and flow of exhaust gas stream 14 . These variations may produce pressure and flow variations within burner unit 26 , which may adversely affect the operation of burner unit 26 .
- Refractory material unit 30 may include one or more refractory materials, which may be configured minimize pressure and flow variations caused by exhaust gas stream 14 , thereby stabilizing a flame produced within burner unit 26 . Further, refractory material unit 30 may be configured to disperse a flame produced by burner unit 26 to facilitate distribution of heat produced by burner unit 26 .
- burner unit 26 is positioned next to exhaust passage 18 , and a portion of tubular member 28 may be disposed within exhaust passage 18 to facilitate heating of exhaust gas stream 14 . It some embodiments, a larger portion of tubular member 28 and/or other components of burner unit 26 may be disposed within exhaust passage 18 . For example, in one embodiment, the portion of tubular member 28 , which includes refractory material unit 30 , may be disposed within exhaust passage 18 .
- FIG. 3 provides a side view of tubular member 28 , including refractory material unit 30 .
- refractory material unit 30 includes a refractory material body 32 and one or more supporting layers 34 , 36 .
- Refractory material body 32 may be disposed with a section of tubular member 28
- one or more supporting layers 34 , 36 may be disposed between a surface of refractory material body 32 and a wall of tubular member 28 .
- a first supporting layer 34 is disposed directly adjacent refractory material body 32
- one or more outer supporting layers 36 are disposed directly adjacent first supporting layers 34 .
- One or more supporting layers 34 , 36 may facilitate retention of refractory material body 32 within tubular member 28 .
- Refractory material body 32 may include a number of suitable materials.
- refractory material body 32 may be produced from a number of suitable metals, ceramics, and/or composite materials.
- the specific materials may be selected based on a variety of properties including, for example, thermal conductivity, heat resistance, strength, fracture toughness, brittleness, cost, machinability, corrosion resistance, and/or any other physical, chemical, and/or thermal property.
- refractory material body 32 may be produced from a material that is able to withstand high temperatures without melting or structural degradation.
- refractory material body 32 may be produced from a number of different ceramic, metal, and/or composite materials configured to withstand temperatures of up to 1000° Celsius, up to 1200° Celsius, up to 1400° Celsius, up to 1600° Celsius, or up to 1800° Celsius.
- refractory material body 32 may include one or more ceramic materials. Numerous suitable ceramics may be selected to produce all or part of refractory material body 32 , and the specific ceramic may be selected based on a number of factors including, for example, machinability, heat resistance, and/or any desired physical property. Suitable ceramics may include, for example, silicon carbide (SiC), yittria-stabilized zirconia, yittria-stabilized zironia alumina, cordierite, kyanite, sodium zirconium phosphate, mullite zirconia, lithium silicate, and/or high purity alumina.
- SiC silicon carbide
- yittria-stabilized zirconia yittria-stabilized zironia alumina
- cordierite kyanite
- sodium zirconium phosphate mullite zirconia
- lithium silicate lithium silicate
- refractory material body 32 may include one or more refractory metals.
- suitable refractory metals may include niobium, tantalum, tungsten, rhenium, molybdenum, as well as other transition metals.
- various combinations of metals may be selected to produce a suitable refractory material body 32 .
- refractory material body 32 may include one or more ceramics produced from one or more refractory metals.
- suitable ceramics may include various oxides, borides, carbides, and/or silicides of one or more metals.
- refractory material body 32 may include a variety of suitable composite materials, including combinations of metals and/or ceramics.
- Refractory material body 32 may include a number of suitable macroscopic configurations.
- refractory material body 32 may include a foam material, a solid material, or a solid material with one or more openings.
- the specific configuration may be selected based on desired physical properties including strength, porosity, thermal conductivity, and/or density. Further, the configuration may also be selected to control the flow of air and/or heat through refractory material body 32 .
- refractory material body 32 may include a foam material.
- foam material may include an open-cell structure configured to facilitate the flow of gases and/or heat through the material.
- the foam structure may be configured to facilitate dispersion of a flame produced within burner unit 26 .
- the foam may include a reticulated structure, which may provide a tortuous flow path through the material, whereby the tortuous flow path may disperse a flame produced within burner unit 26 .
- Suitable foam materials may be selected based on desired material properties.
- a ceramic foam may be selected based on a desired degree of porosity.
- the ceramic foam may have a porosity between about 60% and about 95% by volume. Further, in one embodiment the ceramic foam may have a porosity of at least 80% by volume. Any suitable material may be selected as along as the material has a desired heat resistance, thermal conductivity, and provides a desired degree of flame dispersion.
- Suitable foam materials may be produced using a number of processes.
- suitable foam materials may be produced by depositing a ceramic material on a suitable preform.
- Suitable preforms may include, for example, reticulated polymer foams.
- the ceramic material may be deposited on the preform using a number of suitable processes, including physical vapor deposition (PVD), chemical vapor deposition (CVD), and/or chemical vapor infiltration (CVI) techniques, and the reticulated polymer foam may be pyrolized after deposition of the ceramic material to leave a porous ceramic foam.
- Refractory material body 32 may be produced using any suitable process as long as the process provides the desired material structure and properties.
- one or more supporting layers 34 , 36 may be disposed on a surface of refractory material body 32 .
- the one or more supporting layers 34 , 36 may include at least two layers.
- a first supporting layer 34 may cover an outer surface of refractory material body 32 and may be configured to provide mechanical support to refractory material body 32 and/or to insulate outer supporting layers 36 from refractory material body 32 .
- First supporting layer 34 may include a number of suitable materials.
- first supporting layer 34 may include a number of suitable ceramics, ceramic-fiber mats, refractory metals, and/or composite materials.
- the specific material may be selected based on the material's thermal conductivity, stability at high temperatures, strength, thermal expansion properties, ability to bond with refractory material body 32 or outer supporting layers 36 , and/or any other suitable properties. Any suitable material may be selected for first supporting layer 34 .
- first supporting layer 34 may be selected to have a certain thermal expansion coefficient.
- first supporting layer 34 may be selected to have thermal expansion properties that are similar to the thermal expansion properties of refractory material body 32 .
- first supporting layer 34 may be selected to have thermal expansion properties which may minimize thermal stresses exerted by first supporting layer 34 on refractory material body 32 .
- first supporting layer 34 may be selected based on certain mechanical properties. For example, first supporting layer 34 may be selected to have a certain strength, density, and/or fracture toughness. First supporting layer 34 may be configured to protect refractory material body 34 from vibrations and/or impact during use. Further, first supporting layer 34 may be configured to absorb compressive forces produced by tubular member 28 and/or outer supporting layers 36 and to prevent damage to refractory material body 32 .
- first supporting layer 34 may be selected to insulate outer supporting layers 36 from refractory material body 32 and/or gases located within tubular member 28 .
- first supporting layer 34 may be selected to have a certain thermal conductivity.
- first supporting layer 34 may be produced from a material having a lower thermal conductivity than a material used to produced refractory material body 32 .
- first supporting layer 34 may include a ceramic material.
- the specific ceramic material may be selected based on desired strength, thermal conductivity, cost, and compatibility with refractory material body 32 .
- first supporting layer 34 may include the same ceramic material used to produce refractory material body 32 . Any suitable ceramic material may be selected.
- the specific ceramic used to produce first supporting layer 34 may be selected based on the desired structure and/or physical properties.
- the ceramic may be selected to have a desired strength, flexibility, compressibility, and/or ductility.
- the specific ceramic may be selected to have a certain porosity.
- refractory material body 32 and first supporting layer 34 may both include ceramic materials, and the ceramic included in first supporting layer 34 may have a porosity which is lower than the porosity of refractory material body 32 .
- the lower porosity ceramic included in first supporting layer 34 may produce desired physical properties, including a certain strength, which may provide protection and support for refractory material body 32 .
- first supporting layer may include a ceramic having a porosity less than 20% by volume, less than 15% by volume, less than 10% by volume, or less than 5% by volume.
- First supporting layer 34 may be produced using a number of suitable processes.
- refractory material body 32 may include a ceramic foam material, such as SiC
- first supporting layer 34 may be produced from a ceramic precursor powder, such as a SiC precursor. The powder may be combined with one or more liquids to produce a slurry, which may be applied to a surface of refractory material body 32 .
- the slurry may be applied to a surface of refractory material body 32 using a number of suitable techniques.
- the slurry may be applied by dipping refractory material body 32 into the slurry, by brushing the slurry onto certain sections of refractory material body 32 , or by applying the slurry with a spatula or similar instrument.
- refractory material body 32 includes a foam material
- the slurry may infiltrate the pores of the foam to a certain depth, thereby binding to refractory material body 32 .
- the slurry may infiltrate refractory material body 32 to a depth between about 1 mm and about 10 mm.
- first supporting layer 34 may be produced using a variety of suitable processing techniques including, for example, tape casting and/or tape calendaring.
- a ceramic material may be produced as a strip or patch of material, which may be applied to a surface of refractory material body 32 .
- the material used to produce first supporting layer 34 may be bonded to refractory material body 32 using a variety of high-temperature adhesives, such as Ceramacast 673N SiC based casting material or Ceramabond 813A alumina-silica paste, which are produced by Aremco.
- first supporting layer 34 may be produced using a number of suitable casting or coating materials.
- suitable casting or coating materials may include Aremco's Ceramcast 673N SiC based casting material or PyroPaint 634 SiC.
- the Ceramcast 673N or PyroPaint 634 SiC material may be applied to a surface of refractory material body 32 and optionally heat treated to form a suitable first supporting layer 34 .
- first supporting layer 34 may be desirable to apply to certain sections of refractory material body 32 . Therefore, part of refractory material body 32 may be masked to expose only the surface to which first supporting layer 34 should be applied. In one embodiment, first supporting layer 34 may be applied only to a circumference of refractory material body 32 .
- first supporting layer 34 After applying first supporting layer 34 to refractory material body 32 , it may be desirable to further treat first supporting layer 34 and/or refractory material body 32 . Further treatment may facilitate bonding of first supporting layer 34 to refractory material body 32 . Additionally, further treatment may facilitate formation of a desired structure, composition, and/or physical or thermal properties within first supporting layer 34 . In one embodiment, the treatment may include heat treatment of first supporting layer 34 and/or refractory material body 32 .
- First supporting layer 34 and refractory material body 32 may be heat treated using any suitable process.
- the heat treatment may include sintering the materials in an oven or furnace.
- the specific sintering conditions including, for example, ramp rate, hold time, and/or sintering temperature may be selected based on a number of factors, including the specific materials included in refractory material body 32 and first supporting layer 34 , desired effects of the sintering process, and/or the material size.
- Any suitable heat treatment may be selected to produce a material having desired physical properties.
- Refractory material unit 30 may also include one or more outer supporting layers 36 .
- Outer supporting layers 36 may be configured to further insulate tubular member 28 from refractory material body 32 , to prevent vibration of refractory material body 32 , and to further secure refractory material body 32 within tubular member 28 .
- Outer supporting layers 36 may include a single layer of material or may include multiple layers.
- Outer supporting layers 36 may be produced from a number of suitable materials.
- outer supporting layers 36 may include a number of suitable heat-resistant mats.
- the specific mat material may be selected based on desired physical properties including, for example, strength, heat resistance, specific heat, thermal expansion coefficients, flexibility, compressibility, and/or thermal conductivity.
- the mat material may also be selected based on manufacturability and/or cost.
- outer supporting layers 36 may include a heat-resistant mat including a refractory fiber material.
- a heat-resistant mat including a refractory fiber material.
- suitable refractory fiber materials may be selected including, for example, alumina silicate, aluminoborosilicate, and/or vermiculite.
- the mat may further include combinations of various refractory-fiber materials and/or other additives, such as binders and/or fillers.
- outer supporting layers 36 may be selected based on desired expansion during heating.
- outer supporting layers 36 may include an intumescent material, which may expand when heated. Further, expansion of an intumescent material may produce compressive forces on first supporting layer 34 and/or refractory material body 32 , thereby preventing vibration or loosening of refractory material body 32 .
- outer supporting layer 36 may include a non-intumescent material, which may have little or no expansion at elevated temperatures. A non-intumescent material may be selected to prevent additional compression of refractory material body 32 during heating. For example, refractory material body 32 may be secured by first supporting layer 34 and outer supporting layers 36 , and additional compressive forces may not be necessary. Further, in some embodiments, a non-intumescent material may be selected to prevent excessive compressive forces, which may damage refractory material body 32 .
- Tubular member 28 may include one or more shapes, which may facilitate retention of refractory material body 32 within a region of tubular member 28 .
- tubular member 28 may include a proximal section 37 and an indentation 38 .
- Indentation 38 may include a single circumferential indentation or may include multiple small surface modifications.
- tubular member 28 and first supporting layer 34 may be configured to isolate outer supporting layers 36 from hot gases within tubular member 28 .
- indentation 38 may include circumferential indentation 38 having a diameter which is less than a diameter of first supporting layer 34 .
- Indentation 38 may provide a section of tubular member 28 having a certain internal cross-sectional area, which may be less than a cross-sectional area of the combination of refractory material body 32 and first supporting layer 34 .
- indentation 38 and first supporting layer 34 may provide an insulating barrier between outer supporting layers 36 and gases located within tubular member 28 .
- first supporting layer 34 may be configured to insulate outer supporting layers 36 from refractory material body 32 .
- Indentation 38 may have a number of suitable configurations.
- indentation 38 may be configured to deflect hot gas within proximal section 37 .
- indentation 38 may be configured to deflect hot gases away from outer supporting layer 36 , thereby protecting outer supporting layer 36 from excessive heat produced within burner unit 26 .
- tubular member 28 may further include one or more surface openings 40 , which may provide fluid communication between outer supporting layers 36 and gases located outside of tubular member 28 .
- Surface openings 40 may be positioned at any suitable location along tubular body 28 . Further, surface openings 40 may be configured to facilitate convection and/or conduction of heat away from outer supporting layers 36 , thereby reducing the temperature of outer supporting layers 36 . Alternatively or additionally, surface openings 40 may be configured to cool first supporting layer 32 and/or peripheral regions of refractory material body 32 . Cooling of first supporting layer 32 and/or certain regions of refractory material body 32 may also reduce the temperature of outer supporting layers 36 .
- FIG. 4 illustrates another embodiment for tubular member 28 ′, including refractory material unit 30 ′.
- tubular member 28 ′ includes a proximal section 42 having a first diameter 46 and a distal section 44 having a second diameter 48 .
- refractory material body 32 ′ and supporting layers 34 ′, 36 ′ may be disposed within distal section 44 .
- a retention ring 50 may be provided to secure refractory material body 32 ′ and supporting layers 34 ′, 36 ′ within tubular member 28 ′.
- Retention ring 50 may be secured to tubular member 28 using any suitable process, including laser welding or arc welding.
- FIG. 5 illustrates an exploded view of tubular member 28 ′, as shown in FIG. 4 .
- refractory material body 32 ′ may be disposed with distal section 44 of tubular member 28 .
- the cross-sectional area of refractory material body 32 ′ and/or first supporting layer 34 ′ may be configured to be equal to or greater than the internal cross-sectional area of proximal section 42 of tubular member 28 ′, such that outer supporting layer 36 ′ may be insulated from refractory material body 32 ′ and gases within tubular member 28 ′.
- FIG. 5 also illustrates surface openings 40 ′.
- surface openings 40 ′ may provide fluid communication between outer supporting layers 36 ′ and regions outside of tubular member 28 ′. Further, surface openings 40 ′ may allow convection and/or conduction of heat away from outer supporting layers 36 ′, first supporting layer 34 ′, and or refractory material body 32 ′, thereby reducing the temperature of outer supporting layers 36 ′.
- tubular member 28 , 28 ′ is shown as a cylindrical tube, a number of suitable shapes may be available for tubular member 28 .
- tubular member 28 , 28 ′ may include a square, rectangular, or oval cross-sectional area.
- refractory material body 32 and supporting layers 34 , 36 may also include a number of suitable shapes, which may facilitate placement of refractory material body 34 , 36 within tubular member 28 .
- FIG. 6 illustrates another embodiment for tubular member 28 ′′, proximal section 42 ′, distal section 44 ′, refractory material body 32 ′′, supporting layers 34 ′′, 36 ′′, and retention ring 50 ′.
- tubular member 28 ′′, refractory material body 32 ′′, and supporting layers 34 ′′, 36 ′′ include square cross-sectional areas.
- the cross-sectional area of refractory material body 32 ′′ and first supporting layer 34 ′′ are as large as or larger than the internal square cross-sectional area of proximal section 42 ′.
- distal section 44 ′ may effectively insulate outer supporting layers 36 ′′ from refractory material body 32 ′′ and the interior of tubular member 28 ′′.
- distal section 44 ′ may include one or more surface openings 40 ′′ which may provide fluid communication between outer supporting layers 36 ′′ and regions outside of tubular member 28 ′′, thereby allowing convection and/or conduction of heat away from outer supporting layers 36 ′′.
- FIG. 7 illustrates another embodiment for tubular member 28 ′′′, refractory material body 32 ′′′, and supporting layers 34 ′′′, 36 ′′′.
- tubular member 28 ′′′ includes an inner retention ring 52 configured to secure refractory material body 32 ′′′.
- inner retention ring 52 may define a first section 54 of tubular member 28 ′′′, having a certain cross-sectional area, and refractory material body 32 ′′′ and supporting layers 34 ′′′, 36 ′′′ may be disposed within a second section 56 .
- cross-sectional area of refractory material body 32 ′′′ and first supporting layer 34 ′′′ may be as large as or larger than the internal square cross-sectional area of first section 54 , such that, placement of refractory material body 32 ′′′ and supporting layers 34 ′′′, 36 ′′′ within second section 56 may effectively insulate outer supporting layers 36 ′′′ from refractory material body 32 ′′′ and the interior of tubular member 28 ′′′.
- second section 56 may include one or more surface openings 40 ′′′ which may provide fluid communication between outer supporting layers 36 ′′′ and regions outside of tubular member 28 ′′′, thereby allowing convection and/or conduction of heat away from outer supporting layers 36 ′′′.
- the present disclosure provides a exhaust system refractory material retention system.
- the retention system of the present disclosure may be used to secure any exhaust system component that may be exposed to high temperatures.
- the retention system of the present disclosure may include any refractory material 32 , including ceramic foams used in exhaust system combustion burners.
- the ceramic foam may be covered with one or more supporting layers 34 , 36 .
- the supporting layers 34 , 36 may be produced from a number of readily-available and cost-effective materials, while protecting the foam from vibration and impact during on-highway or off highway use.
- the retention system of the present disclosure may prevent thermal damage to outer supporting layers 36 .
- the system of the present disclosure may insulate outer supporting layers 36 from refractory material 32 and high-temperature gases within combustion burners.
- the system may also include peripherally located openings, which may improve cooling of outer supporting layers 36 by lower-temperature gases. Protection of outer supporting layer 36 may reduce or prevent degradation of outer supporting layers 36 .
- refractory material 32 may be protected from loosening, thereby reducing device failure rates and replacement costs.
Abstract
Description
- This disclosure pertains generally to refractory materials, and more particularly, to systems and methods for securing high-temperature refractory materials within an exhaust system.
- Some exhaust system components are subjected to extreme environmental conditions, including high temperatures. Consequently, a variety of materials have been developed to withstand these high-temperatures, while performing important functions within the exhaust system. Such materials include a number of different ceramics and composite foams, which may form important components of exhaust system combustion burners.
- Although ceramic and composite foams may be particularly well-suited for some conditions, including high temperatures, such foams have some disadvantages. For example, some ceramic foams may be brittle, and over time, the brittle foams may be damaged by repeated mechanical stress. In addition, the high temperature of the foam may damage adjacent structures, including foam retention devices, which may be less resistant to thermal damage. Damage to either the foam or adjacent foam retention devices may cause foam loosening and ultimate device failure. Therefore, improved foam retention devices are needed to prevent damage to the brittle foams and to withstand operational environmental conditions.
- One ceramic support device is described in U.S. Pat. No. 6,077,483, issued to Locker on Jun. 20, 2000 (hereinafter “the '483 patent”). The '483 patent describes a honeycomb ceramic catalyst support. The support includes a substrate skin surrounding a catalyst core. The substrate skin is surrounded by a ceramic barrier coating.
- Although the catalyst support of the '483 patent may provide suitable support for some materials, the support of the '483 patent has several disadvantages. The support of the '483 patent may not adequately protect materials that may be disposed between the catalyst and the exhaust system enclosures. As a result, these materials may degrade when exposed to high temperatures, as produced by exhaust system combustion burners. In addition, the support of the '483 patent may not provide adequate protection to brittle foam materials, as used in some exhaust system components.
- The present disclosure is directed to overcoming one or more of the disadvantages of the prior art material retention devices.
- One aspect of the present disclosure includes a combustion burner refractory material retention system. The system may include a tubular enclosure having a first section and a second section, wherein the first section has an internal cross-sectional area that is less than an internal cross-sectional area of the second section. A refractory material body may be disposed within the tubular enclosure second section. A first support layer may be disposed on a surface of the refractory material body, and at least one outer support layer may be disposed between the refractory material body and a wall of the tubular enclosure second section. The first support layer may form an insulating barrier between the refractory material body and the outer support layer. A cross-sectional area of the combined refractory material body and first support layer may be at least as large as the internal cross-sectional area of the tubular enclosure first section.
- A second aspect of the present disclosure includes a method for securing a refractory material within an exhaust system burner unit. The method may include selecting a refractory material body, applying a first support layer to a surface of the refractory material body, applying at least one outer support layer to a surface of the first support layer, and positioning the refractory material body, first support layer, and at least one outer support layer within a burner tubular enclosure. The tubular enclosure may have a first section which has a first internal cross-sectional area and a second section which has a second internal cross-sectional area, wherein the first internal cross-sectional area is less than the second internal cross-sectional area. A cross-sectional area of the combined refractory material body and first support layer is at least as large as the first internal cross-sectional area.
- A third aspect of the present disclosure includes a work machine. The work machine may include an engine, an exhaust system configured to receive an exhaust gas stream produced by the engine, and a burner unit configured to heat the exhaust gas stream. The burner unit may include a tubular enclosure having a first section and a second section, wherein the first section has an internal cross-sectional area that is less than an internal cross-sectional area of the second section. A refractory material body may be disposed within the tubular enclosure second section. A first support layer may be disposed on a surface of the refractory material body, and at least one outer support layer may be disposed between the refractory material body and a wall of the tubular enclosure second section. The first support layer may form an insulating barrier between the refractory material body and the outer support layer. A cross-sectional area of the combined refractory material body and first support layer may be at least as large as the internal cross-sectional area of the tubular enclosure first section.
- A fourth aspect of the present disclosure includes a work machine. The work machine may include an engine, an exhaust system configured to receive an exhaust gas stream produced by the engine, and a burner unit configured to heat the exhaust gas stream. The burner unit may include a tubular enclosure having a first section and a second section, and a refractory material body may be disposed within the tubular enclosure second section. A first support layer may be disposed on a surface of the refractory material body, and at least one outer support layer may be disposed between the refractory material body and a wall of the tubular enclosure second section. The outer support layer may be insulated from the refractory material body and an interior of the tubular enclosure.
-
FIG. 1 illustrates a work machine according to an exemplary disclosed embodiment. -
FIG. 2 illustrates an engine and exhaust system including a combustion burner system, according to an exemplary disclosed embodiment. -
FIG. 3 provides a side view of a refractory material retention system, according to an exemplary disclosed embodiment. -
FIG. 4 provides a side view of a refractory material retention system, according to an exemplary disclosed embodiment. -
FIG. 5 illustrates an exploded view of the refractory material retention system, according to the embodiment ofFIG. 4 . -
FIG. 6 illustrates a refractory material retention system, according to another exemplary disclosed embodiment. -
FIG. 7 provides a side view of a refractory material retention system, according to another exemplary disclosed embodiment. -
FIG. 1 illustrates awork machine 10 of the present disclosure. As illustrated,work machine 10 includes an off-highway truck. However,work machine 10 may include any work machine that may include an exhaust system refractory material. Such work machines may include, for example, on-highway trucks, ocean vessels, excavators, generator sets, oil drilling equipment, etc.Work machine 10 may include anengine 12, which may supply anexhaust gas stream 14 to an exhaust system 16 (as shown inFIG. 2 ). -
FIG. 2 illustratesengine 12 andexhaust system 16, according to an exemplary disclosed embodiment.Exhaust system 16 may include anexhaust passage 18, which may be configured to carryexhaust gas stream 14 produced byengine 12.Exhaust system 16 may also include a number of catalysts, filters, and/or burners. For example, as shown,exhaust system 16 includes afirst catalyst unit 20, a diesel particulate filter (DPF) 22, and asecond catalyst unit 24.Exhaust system 16 may further include one ormore burner units 26, which may be configured to heatexhaust gas stream 14 and/or other components ofexhaust system 16, such asDPF 22 orsecond catalyst unit 24 within exhaust passage. -
Catalyst units DPF 22 may include any suitable catalyst and/or filter type. For example,catalyst units exhaust system 16 may include additional catalysts, filters, additive supply devices, and/or other suitable exhaust system component, such as fuel-injectors, systems for adding oxidants or reductants, air-intake valves, exhaust valves, temperature sensors, gas sensors, forced-induction systems, and/or any other suitable exhaust system component. -
Burner unit 26 may include a number of suitable burner unit types. For example,burner unit 26 may include a number of different fuel combustors, which may be configured to heatexhaust gas stream 14 to a selected temperature.Burner unit 26 may produce heat by combustion of a number of different fuels, such as diesel fuel or gasoline. Further, the fuel may be supplied toburner unit 26 using a number of suitable fuel-supply systems including, for example, various valves, injectors, atomizers, and/or any other suitable fuel-supply system. In addition, the fuel may be mixed with air provided by any suitable air supply system to facilitate combustion. -
Burner unit 26 may be configured to heatexhaust gas stream 14 and one or more components ofexhaust system 16 to a selected temperature. The desired temperature may be selected to facilitate one or more exhaust system functions. Such exhaust system functions may include, for example, control of one or more catalyst operations or regeneration of one or more exhaust system components. In one embodiment,burner unit 26 may be configured to heatDPF 22 and/or one or moredownstream catalysts 24 to facilitate regeneration ofDPF 22 and/or one or moredownstream catalysts 24. For example, in one embodiment,burner unit 26 may be configured to heatDPF 22 to a temperature that may facilitate removal of soot and/or other deposits fromDPF 22. In one embodiment,burner unit 26 may be configured to heatDPF 22 and/or other components ofexhaust system 16 to temperatures up to 650° Celsius, to temperatures up to 900° Celsius, to temperatures up to 1200° Celsius, to temperatures up to 1500° Celsius, or to temperatures up to 1700° Celsius. - As shown in
FIG. 2 ,burner unit 26 may include atubular member 28, which may be configured to supply heat produced withinburner unit 26 toexhaust passage 18. Further,burner unit 26 may include arefractory material unit 30. Changes in operating conditions ofengine 12 may cause variations in the pressure and flow ofexhaust gas stream 14. These variations may produce pressure and flow variations withinburner unit 26, which may adversely affect the operation ofburner unit 26.Refractory material unit 30 may include one or more refractory materials, which may be configured minimize pressure and flow variations caused byexhaust gas stream 14, thereby stabilizing a flame produced withinburner unit 26. Further,refractory material unit 30 may be configured to disperse a flame produced byburner unit 26 to facilitate distribution of heat produced byburner unit 26. - As shown,
burner unit 26 is positioned next toexhaust passage 18, and a portion oftubular member 28 may be disposed withinexhaust passage 18 to facilitate heating ofexhaust gas stream 14. It some embodiments, a larger portion oftubular member 28 and/or other components ofburner unit 26 may be disposed withinexhaust passage 18. For example, in one embodiment, the portion oftubular member 28, which includesrefractory material unit 30, may be disposed withinexhaust passage 18. -
FIG. 3 provides a side view oftubular member 28, includingrefractory material unit 30. As shown,refractory material unit 30 includes arefractory material body 32 and one or more supportinglayers Refractory material body 32 may be disposed with a section oftubular member 28, and one or more supportinglayers refractory material body 32 and a wall oftubular member 28. In the disclosed embodiment, a first supportinglayer 34 is disposed directly adjacentrefractory material body 32, and one or more outer supportinglayers 36 are disposed directly adjacent first supporting layers 34. One or moresupporting layers refractory material body 32 withintubular member 28. -
Refractory material body 32 may include a number of suitable materials. For example,refractory material body 32 may be produced from a number of suitable metals, ceramics, and/or composite materials. The specific materials may be selected based on a variety of properties including, for example, thermal conductivity, heat resistance, strength, fracture toughness, brittleness, cost, machinability, corrosion resistance, and/or any other physical, chemical, and/or thermal property. - In one embodiment,
refractory material body 32 may be produced from a material that is able to withstand high temperatures without melting or structural degradation. For example,refractory material body 32 may be produced from a number of different ceramic, metal, and/or composite materials configured to withstand temperatures of up to 1000° Celsius, up to 1200° Celsius, up to 1400° Celsius, up to 1600° Celsius, or up to 1800° Celsius. - In one embodiment,
refractory material body 32 may include one or more ceramic materials. Numerous suitable ceramics may be selected to produce all or part ofrefractory material body 32, and the specific ceramic may be selected based on a number of factors including, for example, machinability, heat resistance, and/or any desired physical property. Suitable ceramics may include, for example, silicon carbide (SiC), yittria-stabilized zirconia, yittria-stabilized zironia alumina, cordierite, kyanite, sodium zirconium phosphate, mullite zirconia, lithium silicate, and/or high purity alumina. - In one embodiment,
refractory material body 32 may include one or more refractory metals. For example, suitable refractory metals may include niobium, tantalum, tungsten, rhenium, molybdenum, as well as other transition metals. Further, various combinations of metals may be selected to produce a suitablerefractory material body 32. In addition,refractory material body 32 may include one or more ceramics produced from one or more refractory metals. For example, suitable ceramics may include various oxides, borides, carbides, and/or silicides of one or more metals. Further,refractory material body 32 may include a variety of suitable composite materials, including combinations of metals and/or ceramics. -
Refractory material body 32 may include a number of suitable macroscopic configurations. For example,refractory material body 32 may include a foam material, a solid material, or a solid material with one or more openings. The specific configuration may be selected based on desired physical properties including strength, porosity, thermal conductivity, and/or density. Further, the configuration may also be selected to control the flow of air and/or heat throughrefractory material body 32. - In one embodiment,
refractory material body 32 may include a foam material. A variety of suitable foam structures are available, and the specific foam composition and structure may be selected based on desired weight, cost, thermal conductivity, strength, surface area, fracture resistance, desired application, and/or other physical, chemical, and/or thermal properties. In one embodiment, the foam material may include an open-cell structure configured to facilitate the flow of gases and/or heat through the material. Further, the foam structure may be configured to facilitate dispersion of a flame produced withinburner unit 26. For example, in one embodiment, the foam may include a reticulated structure, which may provide a tortuous flow path through the material, whereby the tortuous flow path may disperse a flame produced withinburner unit 26. - Suitable foam materials may be selected based on desired material properties. For example, in one embodiment, a ceramic foam may be selected based on a desired degree of porosity. In one embodiment, the ceramic foam may have a porosity between about 60% and about 95% by volume. Further, in one embodiment the ceramic foam may have a porosity of at least 80% by volume. Any suitable material may be selected as along as the material has a desired heat resistance, thermal conductivity, and provides a desired degree of flame dispersion.
- Suitable foam materials may be produced using a number of processes. For example, suitable foam materials may be produced by depositing a ceramic material on a suitable preform. Suitable preforms may include, for example, reticulated polymer foams. The ceramic material may be deposited on the preform using a number of suitable processes, including physical vapor deposition (PVD), chemical vapor deposition (CVD), and/or chemical vapor infiltration (CVI) techniques, and the reticulated polymer foam may be pyrolized after deposition of the ceramic material to leave a porous ceramic foam.
Refractory material body 32 may be produced using any suitable process as long as the process provides the desired material structure and properties. - As noted above, one or more supporting
layers refractory material body 32. In one embodiment, the one or more supportinglayers FIG. 3 , a first supportinglayer 34 may cover an outer surface ofrefractory material body 32 and may be configured to provide mechanical support torefractory material body 32 and/or to insulate outer supportinglayers 36 fromrefractory material body 32. - First supporting
layer 34 may include a number of suitable materials. For example, first supportinglayer 34 may include a number of suitable ceramics, ceramic-fiber mats, refractory metals, and/or composite materials. The specific material may be selected based on the material's thermal conductivity, stability at high temperatures, strength, thermal expansion properties, ability to bond withrefractory material body 32 or outer supportinglayers 36, and/or any other suitable properties. Any suitable material may be selected for first supportinglayer 34. - In one embodiment, first supporting
layer 34 may be selected to have a certain thermal expansion coefficient. For example, first supportinglayer 34 may be selected to have thermal expansion properties that are similar to the thermal expansion properties ofrefractory material body 32. Furthermore, first supportinglayer 34 may be selected to have thermal expansion properties which may minimize thermal stresses exerted by first supportinglayer 34 onrefractory material body 32. - In addition, first supporting
layer 34 may be selected based on certain mechanical properties. For example, first supportinglayer 34 may be selected to have a certain strength, density, and/or fracture toughness. First supportinglayer 34 may be configured to protectrefractory material body 34 from vibrations and/or impact during use. Further, first supportinglayer 34 may be configured to absorb compressive forces produced bytubular member 28 and/or outer supportinglayers 36 and to prevent damage torefractory material body 32. - Further, first supporting
layer 34 may be selected to insulate outer supportinglayers 36 fromrefractory material body 32 and/or gases located withintubular member 28. In one embodiment, first supportinglayer 34 may be selected to have a certain thermal conductivity. Particularly, first supportinglayer 34 may be produced from a material having a lower thermal conductivity than a material used to producedrefractory material body 32. - Additionally or alternatively, first supporting
layer 34 may include a ceramic material. The specific ceramic material may be selected based on desired strength, thermal conductivity, cost, and compatibility withrefractory material body 32. For example, in one embodiment, first supportinglayer 34 may include the same ceramic material used to producerefractory material body 32. Any suitable ceramic material may be selected. - The specific ceramic used to produce first supporting
layer 34 may be selected based on the desired structure and/or physical properties. For example, in one embodiment, the ceramic may be selected to have a desired strength, flexibility, compressibility, and/or ductility. Further, the specific ceramic may be selected to have a certain porosity. For example, in one embodiment,refractory material body 32 and first supportinglayer 34 may both include ceramic materials, and the ceramic included in first supportinglayer 34 may have a porosity which is lower than the porosity ofrefractory material body 32. The lower porosity ceramic included in first supportinglayer 34 may produce desired physical properties, including a certain strength, which may provide protection and support forrefractory material body 32. In one embodiment, first supporting layer may include a ceramic having a porosity less than 20% by volume, less than 15% by volume, less than 10% by volume, or less than 5% by volume. - First supporting
layer 34 may be produced using a number of suitable processes. For example, in one embodiment,refractory material body 32 may include a ceramic foam material, such as SiC, and first supportinglayer 34 may be produced from a ceramic precursor powder, such as a SiC precursor. The powder may be combined with one or more liquids to produce a slurry, which may be applied to a surface ofrefractory material body 32. - The slurry may be applied to a surface of
refractory material body 32 using a number of suitable techniques. For example, the slurry may be applied by dippingrefractory material body 32 into the slurry, by brushing the slurry onto certain sections ofrefractory material body 32, or by applying the slurry with a spatula or similar instrument. Further, ifrefractory material body 32 includes a foam material, the slurry may infiltrate the pores of the foam to a certain depth, thereby binding torefractory material body 32. For example, in one embodiment, the slurry may infiltraterefractory material body 32 to a depth between about 1 mm and about 10 mm. - Numerous other suitable processes may be selected to apply first supporting
layer 34 torefractory material body 32. For example, first supportinglayer 34 may be produced using a variety of suitable processing techniques including, for example, tape casting and/or tape calendaring. In tape casting and tape calendaring, a ceramic material may be produced as a strip or patch of material, which may be applied to a surface ofrefractory material body 32. Alternatively or additionally, the material used to produce first supportinglayer 34 may be bonded torefractory material body 32 using a variety of high-temperature adhesives, such as Ceramacast 673N SiC based casting material or Ceramabond 813A alumina-silica paste, which are produced by Aremco. - Further, first supporting
layer 34 may be produced using a number of suitable casting or coating materials. For example, as noted above, a variety of high-temperature adhesives may be applied to the surface ofrefractory material body 32. In one embodiment, an adhesive, casting material, high-temperature paint, and/or coating material may be applied to a surface ofrefractory material body 32, and the adhesive, casting material, high-temperature paint, and/or coating material may form first supportinglayer 34. For example, suitable materials may include Aremco's Ceramcast 673N SiC based casting material or PyroPaint 634 SiC. The Ceramcast 673N or PyroPaint 634 SiC material may be applied to a surface ofrefractory material body 32 and optionally heat treated to form a suitable first supportinglayer 34. - In one embodiment, it may be desirable to apply first supporting
layer 34 to certain sections ofrefractory material body 32. Therefore, part ofrefractory material body 32 may be masked to expose only the surface to which first supportinglayer 34 should be applied. In one embodiment, first supportinglayer 34 may be applied only to a circumference ofrefractory material body 32. - After applying first supporting
layer 34 torefractory material body 32, it may be desirable to further treat first supportinglayer 34 and/orrefractory material body 32. Further treatment may facilitate bonding of first supportinglayer 34 torefractory material body 32. Additionally, further treatment may facilitate formation of a desired structure, composition, and/or physical or thermal properties within first supportinglayer 34. In one embodiment, the treatment may include heat treatment of first supportinglayer 34 and/orrefractory material body 32. - First supporting
layer 34 andrefractory material body 32 may be heat treated using any suitable process. For example, in one embodiment, the heat treatment may include sintering the materials in an oven or furnace. The specific sintering conditions including, for example, ramp rate, hold time, and/or sintering temperature may be selected based on a number of factors, including the specific materials included inrefractory material body 32 and first supportinglayer 34, desired effects of the sintering process, and/or the material size. Any suitable heat treatment may be selected to produce a material having desired physical properties. -
Refractory material unit 30 may also include one or more outer supporting layers 36. Outer supportinglayers 36 may be configured to further insulatetubular member 28 fromrefractory material body 32, to prevent vibration ofrefractory material body 32, and to further securerefractory material body 32 withintubular member 28. Outer supportinglayers 36 may include a single layer of material or may include multiple layers. - Outer supporting
layers 36 may be produced from a number of suitable materials. For example, outer supportinglayers 36 may include a number of suitable heat-resistant mats. The specific mat material may be selected based on desired physical properties including, for example, strength, heat resistance, specific heat, thermal expansion coefficients, flexibility, compressibility, and/or thermal conductivity. The mat material may also be selected based on manufacturability and/or cost. - In one embodiment, outer supporting
layers 36 may include a heat-resistant mat including a refractory fiber material. A number of suitable refractory fiber materials may be selected including, for example, alumina silicate, aluminoborosilicate, and/or vermiculite. The mat may further include combinations of various refractory-fiber materials and/or other additives, such as binders and/or fillers. - The materials included in outer supporting
layers 36 may be selected based on desired expansion during heating. For example, in one embodiment, outer supportinglayers 36 may include an intumescent material, which may expand when heated. Further, expansion of an intumescent material may produce compressive forces on first supportinglayer 34 and/orrefractory material body 32, thereby preventing vibration or loosening ofrefractory material body 32. In another embodiment, outer supportinglayer 36 may include a non-intumescent material, which may have little or no expansion at elevated temperatures. A non-intumescent material may be selected to prevent additional compression ofrefractory material body 32 during heating. For example,refractory material body 32 may be secured by first supportinglayer 34 and outer supportinglayers 36, and additional compressive forces may not be necessary. Further, in some embodiments, a non-intumescent material may be selected to prevent excessive compressive forces, which may damagerefractory material body 32. -
Tubular member 28 may include one or more shapes, which may facilitate retention ofrefractory material body 32 within a region oftubular member 28. For example, as shown inFIG. 3 ,tubular member 28 may include aproximal section 37 and anindentation 38.Indentation 38 may include a single circumferential indentation or may include multiple small surface modifications. - In one embodiment,
tubular member 28 and first supportinglayer 34 may be configured to isolate outer supportinglayers 36 from hot gases withintubular member 28. For example, in the embodiment ofFIG. 3 ,indentation 38 may includecircumferential indentation 38 having a diameter which is less than a diameter of first supportinglayer 34.Indentation 38 may provide a section oftubular member 28 having a certain internal cross-sectional area, which may be less than a cross-sectional area of the combination ofrefractory material body 32 and first supportinglayer 34. Further,indentation 38 and first supportinglayer 34 may provide an insulating barrier between outer supportinglayers 36 and gases located withintubular member 28. Additionally, first supportinglayer 34 may be configured to insulate outer supportinglayers 36 fromrefractory material body 32. -
Indentation 38 may have a number of suitable configurations. For example, in one embodiment,indentation 38 may be configured to deflect hot gas withinproximal section 37. Particularly,indentation 38 may be configured to deflect hot gases away from outer supportinglayer 36, thereby protecting outer supportinglayer 36 from excessive heat produced withinburner unit 26. - In another embodiment,
tubular member 28 may further include one ormore surface openings 40, which may provide fluid communication between outer supportinglayers 36 and gases located outside oftubular member 28.Surface openings 40 may be positioned at any suitable location alongtubular body 28. Further,surface openings 40 may be configured to facilitate convection and/or conduction of heat away from outer supportinglayers 36, thereby reducing the temperature of outer supporting layers 36. Alternatively or additionally,surface openings 40 may be configured to cool first supportinglayer 32 and/or peripheral regions ofrefractory material body 32. Cooling of first supportinglayer 32 and/or certain regions ofrefractory material body 32 may also reduce the temperature of outer supporting layers 36. -
FIG. 4 illustrates another embodiment fortubular member 28′, includingrefractory material unit 30′. In this embodiment,tubular member 28′ includes aproximal section 42 having afirst diameter 46 and adistal section 44 having asecond diameter 48. Further,refractory material body 32′ and supportinglayers 34′, 36′ may be disposed withindistal section 44. In addition, aretention ring 50 may be provided to securerefractory material body 32′ and supportinglayers 34′, 36′ withintubular member 28′.Retention ring 50 may be secured totubular member 28 using any suitable process, including laser welding or arc welding. -
FIG. 5 illustrates an exploded view oftubular member 28′, as shown inFIG. 4 . Again,refractory material body 32′ may be disposed withdistal section 44 oftubular member 28. Further, the cross-sectional area ofrefractory material body 32′ and/or first supportinglayer 34′ may be configured to be equal to or greater than the internal cross-sectional area ofproximal section 42 oftubular member 28′, such that outer supportinglayer 36′ may be insulated fromrefractory material body 32′ and gases withintubular member 28′. -
FIG. 5 also illustratessurface openings 40′. Again,surface openings 40′ may provide fluid communication between outer supportinglayers 36′ and regions outside oftubular member 28′. Further,surface openings 40′ may allow convection and/or conduction of heat away from outer supportinglayers 36′, first supportinglayer 34′, and orrefractory material body 32′, thereby reducing the temperature of outer supportinglayers 36′. - It should be noted, that although
tubular member tubular member 28. For example,tubular member refractory material body 32 and supportinglayers refractory material body tubular member 28. - For example,
FIG. 6 illustrates another embodiment fortubular member 28″,proximal section 42′,distal section 44′,refractory material body 32″, supportinglayers 34″, 36″, andretention ring 50′. In this embodiment,tubular member 28″,refractory material body 32″, and supportinglayers 34″, 36″ include square cross-sectional areas. Further, the cross-sectional area ofrefractory material body 32″ and first supportinglayer 34″ are as large as or larger than the internal square cross-sectional area ofproximal section 42′. In addition, placement ofrefractory material body 32″ and supportinglayers 34″, 36″ withindistal section 44′ may effectively insulate outer supportinglayers 36″ fromrefractory material body 32″ and the interior oftubular member 28″. Further,distal section 44′ may include one ormore surface openings 40″ which may provide fluid communication between outer supportinglayers 36″ and regions outside oftubular member 28″, thereby allowing convection and/or conduction of heat away from outer supportinglayers 36″. -
FIG. 7 illustrates another embodiment fortubular member 28′″,refractory material body 32′″, and supportinglayers 34′″, 36′″. In this embodiment,tubular member 28′″, includes aninner retention ring 52 configured to securerefractory material body 32′″. Further,inner retention ring 52 may define afirst section 54 oftubular member 28′″, having a certain cross-sectional area, andrefractory material body 32′″ and supportinglayers 34′″, 36′″ may be disposed within asecond section 56. Further, the cross-sectional area ofrefractory material body 32′″ and first supportinglayer 34′″ may be as large as or larger than the internal square cross-sectional area offirst section 54, such that, placement ofrefractory material body 32′″ and supportinglayers 34′″, 36′″ withinsecond section 56 may effectively insulate outer supportinglayers 36′″ fromrefractory material body 32′″ and the interior oftubular member 28′″. Further,second section 56 may include one ormore surface openings 40′″ which may provide fluid communication between outer supportinglayers 36′″ and regions outside oftubular member 28′″, thereby allowing convection and/or conduction of heat away from outer supportinglayers 36′″. - The present disclosure provides a exhaust system refractory material retention system. The retention system of the present disclosure may be used to secure any exhaust system component that may be exposed to high temperatures.
- The retention system of the present disclosure may include any
refractory material 32, including ceramic foams used in exhaust system combustion burners. The ceramic foam may be covered with one or more supportinglayers - In addition, the retention system of the present disclosure may prevent thermal damage to outer supporting layers 36. The system of the present disclosure may insulate outer supporting
layers 36 fromrefractory material 32 and high-temperature gases within combustion burners. The system may also include peripherally located openings, which may improve cooling of outer supportinglayers 36 by lower-temperature gases. Protection of outer supportinglayer 36 may reduce or prevent degradation of outer supporting layers 36. In turn,refractory material 32 may be protected from loosening, thereby reducing device failure rates and replacement costs. - It will be apparent to those skilled in the art that various modifications and variations can be made in the disclosed systems and methods without departing from the scope of the disclosure. Other embodiments of the disclosed systems and methods will be apparent to those skilled in the art from consideration of the specification and practice of the embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.
Claims (29)
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PCT/US2006/009849 WO2006118675A1 (en) | 2005-04-29 | 2006-03-16 | Refractory material retention device |
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US (1) | US20060242951A1 (en) |
WO (1) | WO2006118675A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080234123A1 (en) * | 2007-03-23 | 2008-09-25 | Patil Suhas N | Refractory material for reduced SiO2 content |
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US7258842B2 (en) * | 2000-09-20 | 2007-08-21 | Emitec Gesellschaft Fuer Emissionstechnologie Mbh | Catalyst assembly with a fixed catalyst carrier body |
US6833116B2 (en) * | 2000-12-15 | 2004-12-21 | Delphi Technologies, Inc. | Variable flow regulator for use with gas treatment devices |
US20020141907A1 (en) * | 2001-02-09 | 2002-10-03 | Myers Stephen Joe | Short shell highly insulated converter |
US7306772B2 (en) * | 2001-05-02 | 2007-12-11 | Nissan Motor Co., Ltd. | Exhaust gas purification apparatus |
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US20040234428A1 (en) * | 2001-05-25 | 2004-11-25 | Kazutomo Tanahashi | Alumina-silica-based fiber, ceramic fiber, ceramic fiber complex, retaining seal material, production method thereof, and alumina fiber complex production method |
US7240483B2 (en) * | 2004-08-02 | 2007-07-10 | Eaton Corporation | Pre-combustors for internal combustion engines and systems and methods therefor |
US20060070357A1 (en) * | 2004-10-06 | 2006-04-06 | Yonushonis Thomas M | Exhaust aftertreatment filter with residual stress control |
US7323030B2 (en) * | 2004-10-28 | 2008-01-29 | Delphi Technologies, Inc. | Apparatus and method for an exhaust aftertreatment device |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20080234123A1 (en) * | 2007-03-23 | 2008-09-25 | Patil Suhas N | Refractory material for reduced SiO2 content |
WO2008118128A1 (en) * | 2007-03-23 | 2008-10-02 | Refractory Specialties, Incorporated | Refractory material for reduced sio2 content |
US7825052B2 (en) | 2007-03-23 | 2010-11-02 | Refractory Specialties, Incorporated | Refractory material for reduced SiO2 content |
Also Published As
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WO2006118675A1 (en) | 2006-11-09 |
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Owner name: CATERPILLAR INC., ILLINOIS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LIANG, CHO Y.;KISER, MATTHEW THOMAS;THALER, DAVE MICHAEL;AND OTHERS;REEL/FRAME:016538/0626 Effective date: 20050711 |
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Owner name: CATERPILLAR INC., ILLINOIS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:LIANG, CHO Y.;KISER, MATTHEW THOMAS;THALER, DAVE MICHAEL;AND OTHERS;REEL/FRAME:016780/0839 Effective date: 20050711 |
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