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industrial catalytic converter
Handling High Flow Rates in Industrial Catalytic Converters
Industrial catalytic converters. High exhaust mass flow. Stationary engines. Power generation units. Gas turbines. Boilers. Continuous operation.
Flow rate higher than automotive systems. Face velocity control required. Frontal area increased. Pressure drop limited.
Substrate geometry adjusted. Lower cell density. Higher open frontal area. Channel length set for required residence time.
Metallic substrate commonly selected. Thin metal foil. High mechanical strength. Vibration tolerance. Continuous thermal exposure. Ceramic substrate possible. Additional mechanical support required.
Inlet flow condition critical. Non-uniform velocity at inlet. Local high-speed zones. Temperature imbalance. Uneven catalyst aging. Flow straightener or diffuser installed upstream. Multi-brick layout used where required.
Thermal load proportional to flow. Housing design allows uniform temperature distribution. Continuous expansion expected. Expansion gaps and flexible supports applied.
Design objective. Stable flow. Controlled pressure loss. Uniform temperature. Long service life under steady high-flow operation.
Performance and Material Selection for Metallic Substrates in Extreme Heat
Catalytic converter substrate. High-temperature applications. Gasoline and diesel engines. Turbocharged engines. Heavy-duty vehicles. Metallic substrates.
FeCrAl alloys commonly used. Aluminum-based alloys also applied. Material choice affects thermal stability, mechanical strength, and durability. Substrate wall thickness, cell density, and geometry influence heat distribution. Thin walls. High surface area.
Efficient exhaust flow. Thick walls. Improved mechanical resistance. Thermal cycling. Repeated heating and cooling generate stress. Substrate must withstand expansion and contraction.
Coating adhesion critical. Oxidation-resistant metals reduce degradation. Mounting and system integration affect vibration and thermal load. High-flow systems demand stronger metallic cores. Performance testing includes thermal shock, flow resistance, vibration endurance.
Proper substrate material, geometry, and coating ensure long-term reliability in extreme heat environments.