Thermatrix, Inc.

John D Stilger

Richard J Martin

Mark R Holst

Bradley L Edgar

John D Young

Samson C Yee

Michael P Barkdoll

Ann C Heywood

Stephen R McAdams

Marvin M Kilgo

Andrew B King

Christopher B Baer

A method and system for reducing pollutant concentration within an internal combustion engine exhaust stream is disclosed. Soot and products of incomplete combustion in the engine exhaust stream are destroyed by oxidizing them in a flameless thermal oxidizer that contains a matrix of heat-resistant media. Methods and systems for increasing particle residence time within the thermal oxidizer are also disclosed. These techniques include employing electrostatic precipitation, centrifugal force, and particle impaction sections. A method and system for reducing oxides of nitrogen (NOx) emissions is also disclosed. Low NOx concentration may be obtained by adding a SCR system after a thermal oxidizer, by tuning the engine to produce low NOx/high soot and destroying the soot in a thermal oxidizer, and by injecting a reductant into the thermal oxidizer. The flameless thermal oxidizer may be located between the engine and a turbo-charger to enhance thermal efficiency and to reduce turbo-charger wear. The thermal oxidizer comprises longitudinal and radial flow systems, which each may include a reaction wave of the following shapes: planar, cylindrical, Bunsen, Burke-Schumann, and an inverted V. An engineered matrix is disclosed to manipulate the shape of the reaction zone.

Method of reducing internal combustion engine emissions, and system for same

A matrix bed is disclosed in which a non-planar reaction wave front is formed during operation. This is accomplished by heating the matrix bed, containing heat-resistant material, until at least a reaction portion of the matrix bed is above the temperature required for a plurality of reactant gas streams to react. Next, the reactant gas streams are directed through the matrix bed in a manner so as to form at least a Bunsen, Burke-Schumann, inverted-V, or some other type of non-planar reaction wave front at the portion of the matrix bed that is heated above the reactant gas streams reaction temperature. At the non-planar reaction wave front, the reactant gas streams react to produce a reaction product gas stream that is then exhausted from the matrix bed.

Matrix bed for generating non-planar reaction wave fronts, and method thereof

The present invention provides thermal oxidizers containing improved preheating designs and processes for improving the preheating of thermal oxidizers. The processes are practiced by preheating the matrix-bed of matrix materials in a flow path that is opposite in direction to the flow path for the processing fluids through the matrix bed. In such a process, there is a substantial reduction in the time and energy required for the preheating of the matrix bed in comparison to the prior processes using same flow direction preheating.

Thermal oxidizers with improved preheating means and processes for

An improved method and apparatus is provided for thermally reacting chemicals in a matrix bed of porous inert media. The reaction is conducted in an apparatus that is capable of establishing and maintaining a non-planar reaction wave within the matrix bed. The positioning of the non-planar reaction wave permits the interior surfaces of the vessel to be maintained at a temperature at least above 175.degree. F. The apparatus includes a vessel that contains the matrix bed; one or more feed tubes that extend into the matrix bed, where preferably an exterior portion of each of the feed tubes that passes through the vessel is insulated; an exhaust outlet; and a means for heating the matrix bed. The non-planar reaction wave is established by heating at least a portion of the matrix bed to at least the reaction temperature of the chemicals and feeding a process stream containing the chemicals to be reacted into the feed tubes. Upon exiting the feed tubes, the process stream is reacted in a non-planar reaction wave to produce heat and the reacted process stream. The heat from the non-planar reaction wave maintains the interior surfaces of the vessel at a temperature of at least 175.degree. F. during operation of the vessel. The reacted process stream is then directed to the exhaust outlet of the vessel.

Method and apparatus for thermally reacting chemicals in a matrix bed

A process is provided for preparing oxymorphone from morphine by: (1) reacting morphine with (1a) an acyl halide or anhydride to form 3-acylmorphine, or (1b) reacting morphine with benzyl-halide to form 3-benzylmorphine; (2) Oxidizing the 6-hydroxy group of the 3-acyl or 3-benzylmorphine so as to form the corresponding 3-acyl or 3-benzylmorphinone; and thereafter either by (3a) or (3b): (3a) introducing a .beta.-oriented hydroxy group at the 14-position of the 3-acyl- or 3-benzyl-morphinone with aqueous hydrogen peroxide and an acid at a temperature of about 15.degree. to about 70.degree. C. to form the 3-acyl or 3-benzyl-14-hydroxymorphinone; (3b) acylating the 3-acyl or 3-benzyl-morphinone with an acylating agent so as to form the dienol acylate followed by oxidizing the dienol acetate to the corresponding 3-acyl or 3-benzyl-14 -hydroxymorphinone; (4) hydrogenating the 3-acyl-14-hydroxymorphinone with a catalyst so as to form the 3-acyloxymorphone; (5) hydrolyzing the 3-acyl-oxymorphone with aqueous acidic or basic solution to form oxymorphone; (6) hydrogenating the 3-benzyl-14-hydroxymorphinone with a catalyst so as to form oxymorphone.

Method of reducing internal combustion engine emissions, and system for

Matrix bed for generating non-planar reaction wave fronts, and method

Improved methods for the treatment of liquid chemical compounds and process systems for practicing those methods are provided. The methods are practiced by spraying the liquid chemical compounds into a matrix bed of heat resistant materials at temperatures sufficiently high to oxidize the chemical compounds. The sprayed liquid chemical compound is preferably heated to its gaseous state prior to contacting the matrix bed. Processing steps for removing coke deposits in the matrix bed are also provided. The methods are particularly advantageous for the destruction of chemical agents and munitions.

Systems for the treatment of chemical wastes and methods for treating

Processes for the production of hydrogen cyanide from the reaction of methane with ammonia at temperatures above about 800.degree. C. where the reactor contains a matrix bed of heat resistant materials. The product stream produced within the reactor is preferably routed in a countercurrent fashion to the feed stream entering the reactor to preheat the feed stream and to lower the exit temperature of the product stream. Reactors capable of being used to practice such processes are also provided by the invention.

Processes for the synthesis of hydrogen cyanide

Methods and apparatus are provided for destruction of volatile organic compounds ('VOC's') from process fumes having variable amounts of such VOC's wherein a nominal amount of the fumes are passed through an oxidizer for destruction of the VOC's and the hot products from the oxidizer are fed to an afterburner that is principally made up of a matrix bed of heat resistant material. The heat from the oxidized gases heats the matrix bed. Fume flows exceeding the nominal flow are bypassed directly to an inlet port of the afterburner where they are passed through the matrix bed of the afterburner, which has been heated by the oxidized gases from the oxidizer, and are combusted into additional gaseous products in a combustion wave. The system allows for utilization of the heat produced from the oxidation of the nominal flow for destructing fume flows that exceed the nominal flow.

Method and afterburner apparatus for control of highly variable flows

An apparatus and method for the monitoring and abatement of fugitive VOC emissions is disclosed. Suction, generated by a fume pump or a venturi type ejector, pulls air and VOC's from one or more sources of VOC emissions such as the mechanical seals of pumps or compressors. These VOC fumes are collected, separated from any liquids in a knock-out pot, and directed to a flameless combustor/thermal oxidizer comprising a tube packed with heat resistant material and surrounded by an electric heater and thermal insulation. This matrix bed of heat resistant materials is heated to a temperature sufficient to oxidize/destroy the VOC emissions. Thereafter, an optional convective quench section may be used to lower the temperature of the exhaust gases prior to their release to the atmosphere. By monitoring the temperature and/or the amount of power needed, changes in VOC emissions can be detected.

Method and apparatus for control of fugitive VOC emissions

Methods and apparatus are provided for establishing and controlling the stability and movement of a reaction wave of reacting gases in a matrix of solid heat-resistant matter, wherein such reacting gases may be recuperatively pre-heated. At least a portion of the bed is initially preheated above the autoignition temperature of the mixture whereby the mixture reacts upon being introduced into the matrix thereby initiating a self-sustaining reaction region, after which the pre-heating can be terminated. The stability and movement of the wave within the matrix is maintained by monitoring the temperatures along the flowpath of the gases through the bed and adjusting the flow of the gases and/or vapors or air to maintain and stabilize the wave in the bed. The method and apparatus provide for the reaction or combustion of gases to minimize NO.sub.x and undesired products of incomplete combustion. A recuperative heat exchange system is used to preheat the reactants with heat generated by the reaction by channeling hot exhaust gases through the matrix surrounding reactant inlet tubes.

Method and apparatus for recuperative heating of reactants in an

Method and apparatus are provided for establishing and controlling the stability and movement of a reaction wave of reacting gases in a matrix of solid heat-resistant matter. At least a portion of the bed is initially preheated above the autoignition temperature of the mixture whereby the mixture reacts upon being introduced into the matrix thereby initiating a self-sustaining reaction wave, after which, the pre-heating can be terminated. The stability and movement of the wave within the matrix is maintained by monitoring the temperatures along the flowpath of the gases through the bed and adjusting the flow of the gases and/or vapors or air to maintain and stabilize the wave in the bed. The method and apparatus provide for the reaction or combustion of gases to minimize NO.sub.x and undesired products of incomplete combustion.

Growing community of inventors

San Jose, CA, United States of America

John D Stilger