Active microchannel heat exchanger

A chemical processor, comprising:

• (a) an exothermic reaction chamber without microchannels having a first shell defining an exothermic reactant flow path and exhaust flow path, the first shell penetrated with at least one inlet, and an exhaust outlet;
• (b) an exhaust chamber having a second shell with a containment wall defining an exhaust flow path connected to said exhaust outlet, said second shell penetrated by an exhaust chamber outlet, the exhaust chamber having microchannels through which an exhaust flows during operation and wherein said exhaust flows substantially completely through said microchannels;
• and
• (c) a heat exchanger chamber in thermal contact with the exhaust chamber, said heat exchanger chamber having a third shell defining a working fluid flow path containing microchannels and having a third exterior surface penetrated by a working fluid inlet and a working fluid outlet, said working fluid outlet connected to said inlet through which a working fluid flows;
• wherein, during operation,
• (d) wherein said heat exchanger chamber is in thermal contact with the exhaust chamber such that, during operation, heat from the exothermic reaction chamber is convected by an exothermic reaction exhaust through the exhaust chamber and by conduction through the containment wall to the working fluid in the heat exchanger chamber thereby raising a temperature of the working fluid;
• and
• (e) a porous material disposed within the exothermic reaction chamber wherein said porous material fills the exothermic reaction chamber from the top to the bottom of said exothermic reaction chamber.

An active microchannel heat exchanger for heating a working fluid, comprising:

• (a) an exothermic reaction chamber, without microchannels, having a first shell defining an exothermic reactant flow path and exhaust flow path, the first shell penetrated with at least one inlet, and an exhaust outlet;
• (b) an exhaust chamber having a second shell having top and bottom containment walls defining an exhaust flow path connected to said exhaust outlet, said second shell penetrated by an exhaust chamber outlet, the exhaust chamber having microchannels through which an exhaust flows, wherein microchannels in the exhaust chamber have microchannel walls that extend from the top containment wall to the bottom containment wall;
• and
• (c) a heat exchanger chamber in thermal contact with the exhaust chamber, said heat exchanger chamber having a third shell defining a working fluid flow path, said third shell penetrated by a working fluid inlet and a working fluid outlet through which a working fluid flows;
• and
• (d) wherein said heat exchanger chamber is in thermal contact with the exhaust chamber such that, during operation, heat from the exothermic reaction chamber is convected by an exothermic reaction exhaust through the exhaust chamber and by conduction through the containment wall to the working fluid in the heat exchanger chamber thereby raising a temperature of the working fluid;
• and
• (e) a porous material disposed within the exothermic reaction chamber wherein said porous material fills the exothermic reaction chamber from the top to the bottom of said exothermic reaction chamber.

An active microchannel heat exchanger for heating a working fluid, comprising:

• (a) an exothermic reaction chamber having a first shell defining an exothermic reactant flow path and exhaust flow path, the first shell penetrated with at least one inlet, and an exhaust outlet;
• (b) an exhaust chamber having a second shell having top and bottom containment walls defining an exhaust flow path connected to said exhaust outlet, said second shell penetrated by an exhaust chamber outlet, the exhaust chamber having microchannels through which an exhaust flows, wherein microchannels in the exhaust chamber have microchannel walls that extend from the top containment wall to the bottom containment wall;
• and
• (c) a heat exchanger chamber in thermal contact with the exhaust chamber, said heat exchanger chamber having a third shell defining a working fluid flow path, said third shell penetrated by a working fluid inlet and a working fluid outlet through which a working fluid flows;
• and
• (d) a porous material within said exothermic reaction chamber;
• wherein said porous material fills the exothermic reaction chamber from the top to the bottom of said exothermic reaction chamber and
• wherein said heat exchanger chamber is in thermal contact with the exhaust chamber such that, during operation, heat from the exothermic reaction chamber is convected by an exothermic reaction exhaust through the exhaust chamber and by conduction through the containment wall to the working fluid in the heat exchanger chamber thereby raising a temperature of the working fluid.

An active microchannel heat exchanger for heating a working fluid, comprising:

• (a) an exothermic reaction chamber having a first shell defining an exothermic reactant flow path and exhaust flow path, the first shell penetrated with at least one inlet, and an exhaust outlet;
• (b) an exhaust chamber having a second shell having top and bottom containment walls defining an exhaust flow path connected to said exhaust outlet, said second shell penetrated by an exhaust chamber outlet, the exhaust chamber having microchannels through which an exhaust flows, wherein microchannels in the exhaust chamber have microchannel walls that extend from the top containment wall to the bottom containment wall;
• and
• (c) a heat exchanger chamber in thermal contact with the exhaust chamber, said heat exchanger chamber having a third shell defining a working fluid flow path, said third shell penetrated by a working fluid inlet and a working fluid outlet through which a working fluid flows;
• and
• (d) a porous material within said exothermic reaction chamber;
• wherein said porous material fills the exothermic reaction chamber from the top to the bottom of said exothermic reaction chamber and wherein
• said working fluid outlet is connected to said at least one inlet and provides a fluid communication between the heat exchanger chamber and the exothermic reaction chamber.