Ceramatec, Inc.

Akash Akash

Balakrishnan G Nair

Chett Boxley

Qiang Zhao

Joseph Jay Hartvigsen

Merrill Anderson Wilson

Nair Balakrishnan G

An apparatus and method for enhancing the yield and purity of hydrogen when reforming hydrocarbons is disclosed in one embodiment of the invention as including receiving a hydrocarbon feedstock fuel (e.g., methane, vaporized methanol, natural gas, vaporized diesel, etc.) and steam at a reaction zone and reacting the hydrocarbon feedstock fuel and steam in the presence of a catalyst to produce hydrogen gas. The hydrogen gas is selectively removed from the reaction zone while the reaction is occurring by selectively diffusing the hydrogen gas through a porous ceramic membrane. The selective removal of hydrogen changes the equilibrium of the reaction and increases the amount of hydrogen that is extracted from the hydrocarbon feedstock fuel.

Catalytic microchannel reformer

A process for treating fly ash to render it highly usable as a concrete additive. A quantity of fly ash is obtained that contains carbon and which is considered unusable fly ash for concrete based upon foam index testing. The fly ash is mixed with a quantity of spray dryer ash (SDA) and water to initiate a geopolymerization reaction and form a geopolymerized fly ash. The geopolymerized fly ash is granulated. The geopolymerized fly ash is considered usable fly ash for concrete according to foam index testing. The geopolymerized fly ash may have a foam index less than 40%, and in some cases less than 20%, of the foam index of the untreated fly ash. An optional alkaline activator may be mixed with the fly ash and SDA to facilitate the geopolymerization reaction. The alkaline activator may contain an alkali metal hydroxide, carbonate, silicate, aluminate, or mixtures thereof.

Treatment of fly ash for use in concrete

A method for joining multiple ceramic components together is disclosed in one embodiment of the invention as including providing multiple ceramic components, each having a mating surface. A slip containing a mixture of alumina powder and a phosphate-containing reagent is applied to one or more of the mating surfaces. The mean particle size of the alumina powder is tailored to provide improved strength to the bond. Once the slip is applied, the ceramic components may be joined together at their mating surfaces. The joint may then be sintered to react the constituents in the mixture and thereby generate a bond between the ceramic components.

Method for joining ceramic components

A process for treating fly ash to render it highly usable as a concrete additive. A quantity of fly ash is obtained that contains carbon and which is considered unusable fly ash for concrete based upon foam index testing. The fly ash is mixed with an activator solution sufficient to initiate a geopolymerization reaction and for a geopolymerized fly ash. The geopolymerized fly ash is granulated. The geopolymerized fly ash is considered usable fly ash for concrete according to foam index testing. The geopolymerized fly ash may have a foam index less than 35% of the foam index of the untreated fly ash, and in some cases less than 10% of the foam index of the untreated fly ash. The activator solution may contain an alkali metal hydroxide, carbonate, silicate, aluminate, or mixtures thereof.

A method is provided for producing insulation materials and insulation for high temperature applications using novel castable and powder-based ceramics. The ceramic components produced using the proposed process offers (i) a fine porosity (from nano-to micro scale); (ii) a superior strength-to-weight ratio; and (iii) flexibility in designing multilayered features offering multifunctionality which will increase the service lifetime of insulation and refractory components used in the solid oxide fuel cell, direct carbon fuel cell, furnace, metal melting, glass, chemical, paper/pulp, automobile, industrial heating, coal, and power generation industries. Further, the ceramic components made using this method may have net-shape and/or net-size advantages with minimum post machining requirements.

Process for making ceramic insulation

A method is provided for synthesizing beads using starting ceramic, metal, or mineral powders. Typical size of these round beads can range from about 0.1 mm to about 10 mm based on the processing variables. In the method, a slip is obtained which contains a metal, ceramic, and/or mineral powder dispersed in a solvent and an organic binder, such as a grain flour. Droplets of the slip are contacted with heated oil for a sufficient time to form beads. The beads are separated from the oil and dried to remove entrained water. The beads are fired at a temperature sufficient to produce beads possessing desired physical or chemical characteristics. The beads have useful biomedical applications as bone filler materials for bone fixation and bone growth. The beads may be coated with chemical catalyst agents and function as catalyst supports in chemical processes.

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Salt Lake City, UT, United States of America

Akash Akash