# US 7,207,323 B1 · Catalytic core reactor for thermochemical heat recovery > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,207,323 B1 - Document ID: US7207323B1 - Status: Granted - Kind: B1 - Application number: 11/327,094 - Filed: 2006-01-06 - Granted: 2007-04-24 - Earliest claimed: 2006-01-06 - Assignees: Utilization Technology Development, Nfp - Inventors: Klaus Heinrich Hemsath - Web page: https://patentgrep.com/patent/US7207323B1 ## CPC - F01N 5/02: the devices using heat - C01B 3/26: using catalysts - C01B 3/384: with external heating of the catalyst - F02M 25/12: the apparatus having means for generating such gases (using rays and simultaneously generating ozone F02M27/06) - F02M 26/36: with means for adding fluids other than exhaust gas to the recirculation passage; with reformers - F02M 27/02: by catalysts - C01B 2203/0233: the reforming step being a steam reforming step - C01B 2203/0277: containing a catalytic decomposition step - C01B 2203/066: with fuel cells - C01B 2203/0811: by combustion of fuel - C01B 2203/1023: Catalysts in the form of a monolith or honeycomb - F01N 3/2889: {with heat exchangers in a single housing} - F01N 2240/02: a heat exchanger - F01N 2240/30: a fuel reformer - F01N 2330/34: with flow channels of polygonal cross section - Y02P 20/10: Process efficiency - Y02T 10/12: Improving ICE efficiencies - F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16) - C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C} - F02M: SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A fuel conversion system having an exhaust gas generator, such as an engine or a furnace, having a heated exhaust gas outlet, a reactor vessel having a heated exhaust gas inlet in fluid communication with the heated exhaust gas outlet, having a cooled exhaust gas outlet, and containing at least one reactor tube having an exhaust gas inlet in fluid communication with the heated exhaust gas outlet, a convertible fuel inlet, and a converted fuel outlet, and a monolithic fuel conversion catalyst structure substantially centered within the at least one reactor tube and shaped to form at least one flow channel between the monolithic fuel conversion catalyst structure and an inside wall of the at least one reactor tube. ## Claims ### Claim 1 A fuel conversion system comprising: exhaust gas generation means for generating exhaust gases having a heated exhaust gas outlet; a reactor vessel having a heated exhaust gas inlet in fluid communication with said heated exhaust gas outlet, having a cooled exhaust gas outlet, and containing at least one reactor tube, said at least one reactor tube having an exhaust gas inlet in fluid communication with said heated exhaust gas outlet, a convertible fuel inlet, and a converted fuel outlet; and a monolithic fuel conversion catalyst structure substantially centered within said at least one reactor tube and shaped to form at least one flow channel between said monolithic fuel conversion catalyst structure and an inside wall of said at least one reactor tube. ### Claim 2 (depends on 1) A fuel conversion system in accordance with claim 1, wherein said monolithic fuel conversion catalyst structure comprises at least one fuel conversion catalyst and a monolithic substrate material. ### Claim 3 (depends on 2) A fuel conversion system in accordance with claim 2, wherein said monolithic substrate material is a porous substrate material with said fuel conversion catalyst at least one of disposed on an outer surface of said porous substrate material and dispersed within said porous substrate material. ### Claim 4 (depends on 2) A fuel conversion system in accordance with claim 2, wherein said monolithic substrate material is a dense, non-porous material with said fuel conversion catalyst disposed on an outer surface of said monolithic substrate material. ### Claim 5 (depends on 1) A fuel conversion system in accordance with claim 1, wherein said exhaust gas generation means comprises an internal combustion engine. ### Claim 6 (depends on 1) A fuel conversion system in accordance with claim 1, wherein a radial cross-section of said monolithic fuel conversion catalyst structure has a polygonal shape. ### Claim 7 (depends on 6) A fuel conversion system in accordance with claim 6, wherein said radial cross-section has a generally triangular shape. ### Claim 8 (depends on 7) A fuel conversion system in accordance with claim 7, wherein each side of said triangular shape is curved. ### Claim 9 (depends on 6) A fuel conversion system in accordance with claim 6, wherein said radial cross-section comprises a plurality of longitudinal fins arranged in a star-shaped pattern. ### Claim 10 An apparatus comprising: an engine having an exhaust gas outlet; a reactor vessel having a heated exhaust gas inlet in fluid communication with said exhaust gas outlet, having a cooled exhaust gas outlet, and containing at least one bundle of reactor tubes having an exhaust gas inlet in fluid communication with said exhaust gas outlet and having a converted fuel outlet; and a monolithic fuel conversion catalyst structure disposed within at least a portion of said reactor tubes. ### Claim 11 (depends on 10) An apparatus in accordance with claim 10, wherein said engine is an internal combustion engine. ### Claim 12 (depends on 10) An apparatus in accordance with claim 10, wherein a radial cross-section of said monolithic fuel conversion catalyst structure has a polygonal shape. ### Claim 13 (depends on 12) An apparatus in accordance with claim 12, wherein said monolithic fuel conversion catalyst structure has a triangular shaped radial cross-section. ### Claim 14 (depends on 13) An apparatus in accordance with claim 13, wherein each side of said triangular shape is curved. ### Claim 15 (depends on 10) An apparatus in accordance with claim 10, wherein said monolithic fuel conversion catalyst structure comprises at least one fuel conversion catalyst and a monolithic substrate material. ### Claim 16 (depends on 15) An apparatus in accordance with claim 15, wherein said monolithic substrate material is a porous substrate material with said fuel conversion catalyst at least one of disposed on an outer surface of said porous substrate material and dispersed within said porous substrate material. ### Claim 17 (depends on 15) An apparatus in accordance with claim 15, wherein said monolithic substrate material is a dense, non-porous material with said fuel conversion catalyst disposed on an outer surface of said monolithic substrate material. ### Claim 18 (depends on 10) An apparatus in accordance with claim 10, wherein said monolithic fuel conversion catalyst structure is substantially centered within said reactor tube and is shaped to form at least one flow channel between said at least one monolithic fuel conversion catalyst structure and an inside wall of said reactor tube. ### Claim 19 An automotive vehicle comprising: an internal combustion engine having a fuel input and an exhaust gas outlet; a reactor vessel having a heated exhaust gas inlet in fluid communication with said exhaust gas outlet, having a cooled exhaust gas outlet, and containing at least one bundle of reactor tubes having an exhaust gas inlet in fluid communication with said exhaust gas outlet and having a converted fuel outlet; and a monolithic fuel conversion catalyst structure disposed within at least a portion of said reactor tubes. ### Claim 20 (depends on 19) An automotive vehicle in accordance with claim 19, wherein said monolithic fuel conversion catalyst structure is substantially centered within said reactor tubes and is shaped to form at least one flow channel between said at least one monolithic fuel conversion catalyst structure and an inside wall of said reactor tubes. ### Claim 21 (depends on 20) An automotive vehicle in accordance with claim 20, wherein a radial cross-section of said monolithic fuel conversion catalyst structure has a polygonal shape. ### Claim 22 (depends on 21) An automotive vehicle in accordance with claim 21, wherein said monolithic fuel conversion catalyst structure has a triangular shaped radial cross-section. ### Claim 23 (depends on 22) An automotive vehicle in accordance with claim 22, wherein each side of said triangular shape is curved. ### Claim 24 (depends on 19) An automotive vehicle in accordance with claim 19, wherein said monolithic fuel conversion catalyst structure comprises at least one fuel conversion catalyst and a monolithic substrate material. ### Claim 25 (depends on 24) An automotive vehicle in accordance with claim 24, wherein said monolithic substrate material is a porous substrate material with said fuel conversion catalyst at least one of disposed on an outer surface of said porous substrate material and dispersed within said porous substrate material. ### Claim 26 (depends on 24) An automotive vehicle in accordance with claim 24, wherein said monolithic substrate material is a dense, non-porous material with said fuel conversion catalyst disposed on an outer surface of said monolithic substrate material. ### Claim 27 A method for thermochemically converting hydrocarbon and carbonaceous fuels to produce hydrogen and carbon monoxide, the method comprising the steps of: generating exhaust gases using one of an engine and a combustor; transporting a first portion of said exhaust gases to a fuel conversion reactor comprising a reactor vessel containing at least one reactor tube having an exhaust gas inlet, a convertible fuel inlet, and a converted fuel outlet, and a monolithic fuel conversion catalyst structure substantially centered within said at least one reactor tube and shaped to form at least one flow channel between said monolithic fuel conversion catalyst structure and an inside wall of said at least one reactor tube, said first portion of said exhaust gases contacting an outer surface of said at least one reactor tube; transporting a second portion of said exhaust gases through said exhaust gas inlet into said at least one reactor tube; introducing at least one of said hydrocarbon and carbonaceous fuel through said convertible fuel inlet into said at least one reactor tube; converting said at least one of said hydrocarbon and carbonaceous fuel in said at least one reactor tube to a converted fuel comprising hydrogen and carbon monoxide; and removing said converted fuel from said at least one reactor tube through said converted fuel outlet. ### Claim 28 (depends on 27) A method in accordance with claim 27, wherein at least a portion of said converted fuel is returned to a fuel intake of said one of said engine and said combustor. ### Claim 29 (depends on 27) A method in accordance with claim 27, wherein a temperature within said at least one reactor tube is substantially uniform. ### Claim 30 (depends on 27) A method in accordance with claim 27, wherein a mass concentration in a radial direction within said at least one reactor tube is substantially uniform. ### Claim 31 (depends on 27) A method in accordance with claim 27, wherein atoms comprising said second portion of exhaust gases, said at least one of said hydrocarbon and said carbonaceous fuel, and said converted fuel have a substantially uniform residence time within said at least one reactor tube.