Integrated reactors, methods of making same, and methods of conducting simultaneous exothermic and endothermic reactions

An integrated reactor, comprising:

• a first reaction chamber having a width of 2 mm or less, wherein there is an open path through the first reaction chamber, wherein the first reaction chamber has an internal volume comprising 5 to 95 vol. % of porous catalyst and 5 to 95 vol. % of open space;
• and a second reaction chamber having a width of 2 mm or less, wherein there is an open path through the second reaction chamber, wherein the second reaction chamber has an internal volume comprising a catalyst and at least 5 vol. % of open space;
• and a reaction chamber wall separating the first chamber and the second chamber;
• and wherein the integrated reactor possesses a NOx output characteristic of less than 100 ppm as measured according to the Standard NOx Test Measurement.

A method of making an integrated reactor, comprising:

• providing a single block of thermally conductive material;
• forming at least one first microchannel by electro-discharge machining;
• forming at least one second microchannel;
• placing at least one catalyst capable of catalyzing an exothermic reaction in the at least one first microchannel;
• placing at least one catalyst capable of catalyzing an endothermic reaction in the at least one second microchannel;
• wherein the first microchannel and second microchannel are separated by less than 1 cm.