Other

W. R. Grace Co.-Conn.

Catacel Corporation

Camet, Inc.

W. R. Grace Co.

Oxy-Catalyst, Incorporated

United Technologies Corporation

Engelhard Corporation

Englehard Corporation

William B Retallick

Richard C Cornelison

William Alan Whittenberger

William R Alcorn

Joseph J Sangiovanni

Rasto Brezny

James George Miller

Robert J Hall

Mark R Strenger

F Curtiss Dunbar

Brian A Knight

Paul K Predecki

Stuart W Churchill

Raymond J Gorte

James W Patten, Jr

Paul John Westgate

Harold R Smithson

In a downhole steam generator, hydrogen, oxygen, and water are separately injected into an oil well. The hydrogen and oxygen are made to react, either with the aid of a catalyst or due to an electric spark. Heat from the reaction converts the water in the area into steam, which is then used to enhance the production of the oil well. The hydrogen may be produced at the surface of the well by the steam reforming of a hydrocarbon. The hydrogen injected into the well may be provided as part of a reformate mixture produced by the steam reforming process. The water is preferably atomized by the stream of oxygen immediately before ignition, so as to provide a maximum surface area for heat absorption.

Downhole steam generator

A hydrogen generator is formed of a strip of corrugated material that has been folded back and forth upon itself to define a monolith having multiple fluid flow regions. At least one of these regions is used for combustion, and at least one of these regions is used for steam reforming. Water is introduced into another fluid flow region, so as to receive heat from products of combustion, and to be converted into steam. The steam is directed into one or more regions used for steam reforming, so as to produce hydrogen for use in a fuel cell. In its more general form, the invention includes a compact heat exchanger, formed of a strip of corrugated material that has been folded back and forth upon itself, the heat exchanger being capable of transferring heat among three or more fluid streams.

Hydrogen generator

A compact steam reformer produces hydrogen to power a fuel cell, such as can be used in a vehicle. The steam reformer includes a first channel, at least partly coated with a steam reforming catalyst, and a second channel, at least partly coated with a combustion catalyst, the channels being in thermal contact with each other. Heat from the combustion is used in the steam reforming reaction. In another embodiment, the gas streams feeding the reforming and combustion channels pass through a valve which reverses the gas streams periodically. The combustion channel becomes the reforming channel, and vice versa, so that carbon deposits in the former reforming channel are burned off. This arrangement enables the reforming reaction to continue indefinitely at peak efficiency.

Regenerative autothermal catalytic steam reformer

A catalytic combustor for a gas turbine includes a stack of metal strips, each strip having an inlet end and an outlet end. The inlet ends of both sides of the strip are uncoated, to limit the temperature and maintain rigidity of the strip at the inlet end. In one embodiment, both sides of the strip have a light-off band, coated with catalyst, and adjacent to the uncoated inlet band. One side of the strip (Side A) also includes at least one combustion band, while the other side (Side B) has no corresponding coated band. The strips are arranged such that Side A of a given strip inside the stack faces Side A of an adjacent strip, and Side B of a strip inside the stack faces Side B of an adjacent strip. The resulting structure prevents overheating of the combustor, maintains its rigidity, and reduces the pressure drop through the combustor.

Catalytic combustor for a gas turbine

A combustion system for a gas turbine includes a steam reformer and a combustor connected in series. A portion of the incoming fuel is diverted to the steam reformer, the balance passing directly to the combustor. The effluent from the steam reformer, which effluent includes a significant amount of hydrogen, is combined with the unreformed fuel entering the combustor. The result is a hot combustion gas which contains very little NOx.

Low NOX combustor for a gas turbine

A catalyst composition which includes palladium and zirconium is formed as a suspension which can be coated onto a metal strip. The composition is formed by combining palladium nitrate with a solution of an alkyl ammonium hydroxide, and mixing the combination with a hydrous zirconium oxide, to form the suspension. The alkyl ammonium hydroxide is preferably tetramethylammonium hydroxide or tetrabutylammonium hydroxide. Nitric acid may be added to the palladium nitrate. The resulting composition shows superior activity and good adhesion to a metal strip. The composition can catalyze a combustion reaction, as well as a steam reforming reaction.

Catalyst comprising palladium and zirconia

A catalytic combustor burns a fuel-air mixture which is not preheated. The combustor includes a strip or strips of metal which define a plurality of alternating wide and narrow channels. The channels contain corrugated strips which maintain the spacing of the channels. A catalyst coating is deposited only in the wider channels, the narrower channels remaining un-catalyzed. The strip or strips can be heated resistively to start the combustion. Once the combustion is started, the electric current is stopped, and the combustion continues. The combustor is useful in a home heating appliance such as a gas furnace. In another embodiment, in which the combustor is used in a high-temperature environment such as in a gas turbine, the catalyst can be deposited in the small channels only, so as to limit the amount of catalytic combustion.

Catalytic combustor and method of operating same

A catalytic combustor is formed of a plurality of segments which are enclosed within a canister. Each segment includes a metal strip which is folded back and forth upon itself. The strip is coated with catalyst on only one side, and the strip is brazed or welded to the canister only on the uncoated side. The segments of the combustor substantially fill the cross-section of the canister, but these segments are not physically joined to each other. The structure described above makes it possible to make the combustor relatively flat, having a length to diameter ratio of 0.25 or less. The catalytic combustor of the present invention is especially useful in a gas turbine, where space is limited, and where catalytic combustion is useful in preventing the formation of NOx.

An improved honeycomb body having a perimeter which encloses the cross section of the honeycomb body. The honeycomb is formed by folding a strip of metal foil back and forth upon itself to provide folds, the foil having corrugations whereby the corrugations maintain the spacing between the folds. One end and only one end of each fold terminates on the perimeter of the body, the cross section of the body being completely filled with folds. The honeycomb body has increased structural and mechanical integrity and is especially useful as a catalyst support for preparing an automotive catalyst.

Metal honeycomb body

A barrier is formed on a metal substrate by coating the substrate with a metal oxide, calcining the substrate, impregnating the coated substrate with an acid, and calcining the impregnated coating at a temperature high enough to cause the metal oxide to form the barrier. The resulting barrier acts as an excellent electrical insulator, and also provides improved resistance to abrasion, and improved adhesion to the substrate. The particles forming the barrier also have improved cohesion. The metal substrate having the barrier of the present invention can be used in electrically heated catalytic converters, where it is necessary to provide closely spaced layers of metal foil that must be electrically insulated from each other. The invention can also be used in other metal structures intended to be placed in the exhaust stream of a chemical or manufacturing process or an engine.

Barrier for a metal substrate

The surface of an aluminide is treated to make it less chemically reactive. In particular, this treatment inhibits oxidation of the aluminide at high temperatures. According to the invention, one coats the aluminide with a solution that containing phosphoric or phosphorous acid, and then one heats the aluminide, so as to calcine the coating. The phosphoric or phosphorous acid reacts with the aluminide to form a surface that resists oxidation. One can use this process to coat the blades of a gas turbine, or to coat other aluminide structures intended for use in high-temperature environments.

Aluminide for use in high-temperature environments

An air cleaner includes first and second support structures connected in series. The first support structure has a coating made of a material which absorbs organic contaminants from air passing through it. A combustion catalyst coats the second support structure. The air cleaner thus removes organic contaminants from the air at ambient temperature, when air passes through the first support structure. When the air cleaner has operated for an extended time, the absorbent coating becomes filled with contaminants. One then regenerates the air cleaner by applying heat to both support structures, to evolve the organic contaminants from the first support structure and to burn off these contaminants catalytically in the second support structure. In one embodiment, the support structure has the form of an electrically heated converter, in which one uses an electric current to provide the heat needed for regeneration. Only a relatively small volume of air becomes heated during regeneration. A suitable system of valves and sensors assures that air flows through the desired paths during the cleaning and regeneration phases. Other embodiments of the invention include a single support structure, which may or may not have a catalyst coating.

Air cleaner capable of catalytic regeneration

A method of making a novel structure for the first stage of a multiple-stage combustion, in which a metal strip is coated with a catalyst on only one side. The strip is also corrugated with a herringbone pattern. The strip is then folded back and forth upon itself to form a reactor of a desired cross-section. The reactor has rows of channels that are formed between the layers of the metal. The single coated side of the metal defines the walls of the channels in every other row. The fuel-air mixture that flows through the coated channels is combusted. The fuel-air mixture that flows through the uncoated channels is not combusted, and cools the catalyzed surfaces. The herringbone corrugations prevent the layers of metal from nesting together, and also define zigzag paths for flow of combustion gas. The one or more stages subsequent to the ignition stage can employ a catalyst capable of operating at the very high temperatures present in gas turbines. The subsequent stages can also be non-catalytic. Thus, the first stage provides catalytic ignition, and the subsequent stages complete the combustion.

Method of making a combustion apparatus for high-temperature environment

A catalytic reactor, used as the ignition stage for a multi-stage combustor, is made by the following method. Alternate sides of a metal strip are first coated with a combustion catalyst, in such a manner that at any point on the strip, one side is coated and the other side is not coated. Then the strip is folded back and forth upon itself in a zigzag pattern, to produce the reactor. The strip has corrugations which keep adjacent portions of the strip spaced apart when the strip has been folded. The reactor made by this method has an extended useful life, in part because it does not become so hot that the catalyst becomes deactivated.

Method for making an ignition stage for a high temperature combustor

This invention includes a multiple-stage combustion apparatus which can be used in a high-temperature environment, such as with a gas turbine. In particular, the invention includes a novel structure for the first stage of such apparatus, and a method of making that first stage. The first stage, which is an ignition stage, is a reactor formed of a metal strip which is coated with a catalyst on only one side. The strip is also corrugated with a herringbone pattern. The strip is then folded back and forth upon itself to form a reactor of a desired cross-section. The reactor has rows of channels that are formed between the layers of the metal. The single coated side of the metal defines the walls of the channels in every other row. The fuel-air mixture that flows through the coated channels is combusted. The fuel-air mixture that flows through the uncoated channels is not combusted, and cools the catalyzed surfaces. The herringbone corrugations prevent the layers of metal from nesting together, and also define zigzag paths for flow of combustion gas. The one or more stages subsequent to the ignition stage can employ a catalyst capable of operating at the very high temperatures present in gas turbines. The subsequent stages can also be non-catalytic. Thus, the first stage provides catalytic ignition, and the subsequent stages complete the combustion.

Growing community of inventors

West Chester, PA, United States of America

William B Retallick