Chemical reactor and fuel processor utilizing ceramic technology

A chemical reactor comprising:

• a monolithic three-dimensional multilayer ceramic structure, the monolithic three-dimensional multilayer ceramic structure comprised of a plurality of thin ceramic layers assembled to provide for at least one ceramic cavity having a geometric surface area, and thereby defining a closed reaction zone;
• a porous ceramic support layer cofired with the monolithic three-dimensional multilayer ceramic structure and formed within the at least one ceramic cavity, the porous ceramic support layer characterized as having a real surface area greater than the geometric surface area of the ceramic cavity;
• and
• a catalyst material formed in combination with the porous ceramic support layer, the catalyst characterized as providing for a chemical reaction which converts input chemical reactants into chemical products and by-products in the output.

A method of forming a chemical reactor comprising the steps of:

• providing a ceramic material;
• defining therein the ceramic material, at least one ceramic cavity, the at least one ceramic cavity having a geometric surface area;
• depositing therein the at least one ceramic cavity a porous ceramic support layer;
• cofiring the ceramic material and the porous ceramic support layer to form a ceramic carrier structure having the at least one ceramic cavity defined therein;
• depositing a catalyst material in contact with the porous ceramic support layer, thereby forming an immobilized catalyst characterized as providing a chemical reaction which converts input chemical reactants into chemical products and by-products in the output.

A fuel processor comprising:

• a ceramic carrier defining a plurality of chemical reactors, including a fuel reforming reactor and an integrated chemical combustion reactor, the fuel reforming reactor including a reaction zone including a reforming catalyst and the integrated chemical reactor thermally coupled to the reaction zone, wherein each of the plurality of chemical reactors has defined therein a ceramic cavity, a porous ceramic support layer, and an immobilized catalyst arranged to convert input chemical reactants into chemical products and by-products in the output to produce heat and hydrogen enriched gas;
• a plurality of inlet channels for liquid fuel;
• a plurality of outlet channels for hydrogen enriched gas;
• and
• an integrated fuel cell, including an anode in microfluidic communication with the outlet channel of the fuel reforming reactor.