Support structure for a catalyst in a combustion reaction chamber

A method for securing within a combustion reaction chamber defined by a reaction chamber wall, a monolithic catalyst structure made up of a multiplicity of longitudinally disposed channels with inlet and outlet ends for passage of a flowing gas mixture and having a longitudinal axis in the direction of gas mixture flow, said flowing gas mixture exerting an axial load on the catalyst structure, which comprises inserting into the reaction chamber at the outlet end of the catalyst structure or at both the outlet end and inlet end of the catalyst structure, a monolithic open cellular structure in which the walls of the cells are formed by strips of a high temperature resistant metal or ceramic material to afford cellular openings which are at least as large as the openings formed by the catalyst structure channels at their inlet and outlet ends, said monolithic open cellular structure being:

• (a) positioned and configured to abut against one end of the catalyst structure and extend in a direction parpendicular to the longitudinal axis of the catalyst structure to essentially cover the end face of the catalyst structure, with the cellular openings of the monolithic open cellular structure being in fluid communication with the channels of the catalyst structure;
• and
• (b) secured on an outer periphery to the reaction chamber wall by an attachment means fixed to the reaction chamber wall which holds the monolithic open cellular structure in place while allowing differential thermal expansion of the monolithic open cellular structure in an outward direction towards to reaction chamber wall such that the axial load which is placed on the monolithic open cellular structure by the catalyst structure on passage of the flowing gas mixture is transferred to the reaction chamber wall thereby limiting axial movement of said catalyst structure.

A process for the combustion of a hydrocarbonaceous or other combustible fuel to form a hot gas product wherein the fuel is at least partially combusted, the process comprising the steps of:

• (a) forming a mixture of the fuel with an oxygen-containing gas;
• and
• (b) passing the oxygen-containing gas and fuel mixture as a flowing gas stream through a monolithic catalyst structure positioned in a combustion reaction chamber defined by a reaction chamber wall, said catalyst structure made up of a multiplicity of longitudinally disposed channels for passage of said flowing gas stream and having a longitudinal as in the direction of gas mixture flow, said catalyst structure being stablized in said reaction chamber by means of a monolithic open cellular structure in which the walls of the cells are formed by strips of a high temperature resistant metal or ceramic material to afford cellular openings which are at least as large as the openings formed by the catalyst structure channels at their inlet and outlet ends, said monolithic open cellular structure being:
• (i) placed at the outlet end of catalyst structure or at both the inlet end and the outlet end of the catalyst structure;
• (ii) positioned and configured to abut against one end of the catalyst structure and extend in a direction perpendicular to the longitudinal axis of the catalyst structure to essentially cover the end face of the catalyst structure, with the cellular openings of the monolithic open cellular structure being in fluid communication with the channels of the catalyst structure;
• and
• (iii) secured on an outer periphery to the reaction chamber wall by an attachment means fixed to the reaction chamber wall which holds the monolithic open cellular structure in place while allowing for differential thermal expansion of the monolithic open cellular structure in an outward direction towards the reaction chamber wall thereby limiting the axial movement of said catalyst structure parallel to the longitudinal axis of said catalyst structure.

A support structure for securing within a combustion reaction chamber defined by a reaction chamber wall, a multi-stage monolithic catalyst structure made up of a multiplicity of longitudinally disposed channels with inlet and outlet ends from each stage for passage of a flowing gas mixture which exerts an axial load on the catalyst structure in the direction of gas flow with the catalyst structure having a longitudinal as in the direction of gas mixture flow, said support structure comprising a monolithic open cellular structure wherein the walls of the cells are formed by strips of a high temperature resistant metal or ceramic material to afford cellular openings which are at least a large as the openings formed by the catalyst structure channels at their inlet and outlet, ends, said monolithic open cellular structure being:

• (a) placed at the outlet end of each stage of the catalyst structure, or at the inlet end of the first stage of the catalyst structure and the outlet end of one or more of the catalyst stages including the final catalyst stage in the catalyst structure;
• (b) positioned and configured to abut against one end of the catalyst structure and extend in a direction perpendicular to the longitudinal axis of the catalyst structure to essentially cover the end face of the catalyst structure, with the cellular openings of the monolithic open cellular structure being in fluid communication with the channels for the catalyst structure;
• and
• (c) secured on an outer periphery to the reaction chamber wall by an attachment means fixed to the reaction chamber wall which hold the monolithic open cellular structure in place while allowing for differential thermal expansion of the monolithic open cellular structure in an outward direction towards the reaction chamber wall such that the axial load which is placed on the monolithic open cellular structure by the catalyst structure on passage of the flowing gas mixture is transferred to the reaction chamber wall thereby limiting axial movement of said catalyst structure parallel to the longitudinal axis of said catalyst structure.