Catalytica, Inc.

Walter Wiley

Sarento George Nickolas

James C Schlatter

Ralph Dalla Betta

An improved catalytic reactor for high temperature reactions having a reaction chamber and a monolithic catalyst structure disposed in the reaction chamber is disclosed wherein the catalyst structure has a multiplicity of longitudinally disposed channels formed by thin metal substrate walls which expand on exposure to the heat generated in high temperature reactions and reactor also includes a monolithic open cellular support structure disposed in the reaction chamber having a multiplicity of longitudinally disposed passageways formed by strips of high temperature resistant metal or ceramic material with the support structure being secured on its outer periphery to the wall of the reaction chamber to limit movement along the longitudinal axis, and being positioned at and abutting against the outlet end of the catalyst structure. The improved structure also includes: (a) an annular space between the outer periphery of the catalyst structure and the wall of the reaction chamber which is sized to accommodate the thermal expansion of the catalyst structure which occurs during the high temperature reaction without allowing the catalyst structure to be deformed by pressing against the reaction chamber wall; (b) a plurality of flexible flanges which extend from the outer peripheral surface of the catalyst structure to the inner surface of the reaction chamber tubular wall to substantially block the flow of reaction gas mixture through the annular space; (c) a radial centering assembly which includes cooperating struts and splines mounted on the chamber wall and the support structure to permit thermal expansion of the support structure; (d) an optional centering support structure for transferring a portion of the force from the flow of gases onto a second support structure positioned on the inlet side of the catalyst structure; and (e) an outer metal band for the support structure having slots formed therein to provide sufficient flexibility for thermal expansion of the support structure while providing additional support therefor.

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Palm Beach Gardens, FL, United States of America

Walter Wiley