Matrix bed for generating non-planar reaction wave fronts, and method thereof

A method of increasing the overall volumetric reaction rate within a matrix bed comprising heat-resistant material and having a non-planar surface, comprising the steps of:

• (a heating the matrix bed until at least a reaction portion of the matrix bed is above the temperature required for one or more reactant gas streams to react;
• (b directing the reactant gas streams through the non-planar surface of the matrix bed and into the matrix bed in a plurality of directions in a manner so as to form at least a non-planar reaction wave front in the reaction portion of the matrix bed and a reaction product gas stream;
• and
• (c exhausting the reaction product gas stream from the matrix bed.

A method of increasing the overall volumetric reaction rate within a matrix bed comprising heat-resistant material by forming a non-planar reaction wave front therein, comprising the steps of:

• (a heating the matrix bed until at least a reaction portion of the matrix bed is above the temperature required for one or more reactant gas streams to react;
• (b directing the reactant gas streams through the reaction portion of the matrix bed to create a reaction gas product stream, wherein at least a portion of the matrix bed comprises a plurality of flow control portions arranged to enable forming the non-planar reaction wave front;
• and
• (c exhausting the reaction product gas stream from the matrix bed.

A method of increasing the overall volumetric reaction rate within a matrix bed comprising heat-resistant material by forming at least an inverted-V reaction wave front therein, comprising the steps of:

• a) heating the matrix bed until at least a reaction portion of the matrix bed is above the temperature required for one or more reactant gas streams to react;
• b) directing the reactant gas streams through the reaction portion of the matrix bed such that:
• i) one or more wave holders anchor the inverted-V reaction wave front;
• and
• ii) a reaction product gas stream is produced;
• and
• c) exhausting the reaction product gas stream from the matrix bed.

A thermal reactor for optimizing the reaction rate of one or more reactant gas streams by forming one or more Bunsen reaction wave fronts therefrom, comprising:

• a) a matrix bed of heat-resistant material comprising at least a matrix bed surface having an upstream side and a downstream side adjacent to the matrix bed;
• b) heating means for heating the matrix bed until at least a reaction portion of the matrix bed is above the temperature required for the reactant gas streams to react and to form a reaction product gas stream therefrom;
• c) gas entry means for directing the reactant gas streams into the matrix bed through one or more introduction locations located downstream of the matrix bed surface and forming the Bunsen reaction wave fronts in the matrix bed reaction portion;
• d) temperature means for monitoring a temperature profile of the matrix bed;
• e) adjusting means for varying the reactant gas streams flowrates in response to the monitored temperature profile;
• and
• f) exit means for the reaction product gas stream to exit the matrix bed.

A thermal reactor for optimizing the reaction rate of one or more reactant gas streams by forming one or more inverted-V reaction wave fronts therefrom, comprising:

• a) a matrix bed of heat-resistant material comprising at least a matrix bed surface having an upstream side and a downstream side adjacent to the matrix bed;
• b) heating means for heating the matrix bed until at least a reaction portion of the matrix bed is above the temperature required for the reactant gas streams to react and to form a reaction product gas stream therefrom;
• c) gas entry means for directing the reactant gas streams into the matrix bed and through the matrix bed reaction portion;
• d) wave holder means disposed in the matrix bed reaction portion for anchoring the inverted-V reaction waves fronts;
• e) temperature means for monitoring a temperature profile of the matrix bed;
• f) control means for varying the reactant gas streams' flowrates in response to the monitored temperature profile;
• and
• g) exit means for the reaction product gas stream to exit the matrix bed.