# US 7,608,227 B2 · Catalyst structure

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- Number: US 7,608,227 B2
- Document ID: US7608227B2
- Status: Granted
- Kind: B2
- Application number: 11/677,012
- Filed: 2007-02-20
- Published: 2007-08-23
- Granted: 2009-10-27
- Earliest claimed: 2006-02-23
- Assignees: CompactGTL plc
- Inventors: David James West
- Web page: https://patentgrep.com/patent/US7608227B2

## CPC

- B01J 19/249: {Plate-type reactors}
- B01J 19/32: Packing elements in the form of grids or built-up elements for forming a unit or module inside the apparatus for mass or heat transfer
- B01J 37/0221: {of particles}
- F01N 3/2814: {all sheets, plates or foils being corrugated}
- B01J 2219/2453: Plates arranged in parallel
- B01J 2219/2459: Corrugated plates
- B01J 2219/246: Perforated plates
- B01J 2219/2462: the reactants being in indirect heat exchange with a non reacting heat exchange medium
- B01J 2219/2465: Two reactions in indirect heat exchange with each other
- B01J 2219/247: Feeding means for the reactants
- B01J 2219/2479: Catalysts coated on the surface of plates or inserts
- B01J 2219/2485: Metals or alloys
- B01J 2219/2486: Steel
- B01J 2219/2487: Ceramics
- B01J 2219/2493: Means for assembling plates together, e.g. sealing means, screws, bolts
- B01J 2219/3221: Corrugated sheets
- B01J 2219/32213: Plurality of essentially parallel sheets
- B01J 2219/32237: Sheets comprising apertures or perforations
- B01J 2219/32408: Metal
- B01J 2219/32466: comprising catalytically active material
- B01J 2219/32475: involving heat exchange
- B01J 2219/3281: Pleating
- F01N 2330/04: Methods of manufacturing
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- 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)

## Abstract

A catalyst structure comprises a foil strip (10) acting as the substrate, and which has been cut and shaped so as to define a multiplicity of peaks (15) and troughs (16) each with its axis extending across the foil, such that peaks and troughs alternate across the foil strip (10). Such a corrugated substrate may be provided with a ceramic coating incorporating a catalytic material. The corrugations enhance turbulence within a flow channel of a compact catalytic reactor.

## Claims

### Claim 1

A compact catalytic reactor defining a multiplicity of first and second flow channels arranged alternately in the reactor, for carrying first and second fluids, respectively, wherein at least the first fluids undergo a chemical reaction; each first flow channel being rectangular and having a width, and containing a removable gas-permeable catalyst structure, the catalyst structure incorporating a metal foil which has been cut and shaped so as to define a multiplicity of peaks and troughs, the width of the foil being selected in relation to the width of the first flow channel to provide enough clearance that the foil can be slid freely into the first channel, wherein each of said peaks and troughs has its axis extending across the foil, such that peaks and troughs alternate across the width of the foil.

### Claim 2 (depends on 1)

A reactor as claimed in claim 1 wherein along the length of the foil there are lines of peaks and lines of troughs.

### Claim 3 (depends on 1)

A reactor as claimed in claim 1 wherein along the length of the foil there are lines along which peaks and troughs alternate.

### Claim 4 (depends on 1)

A reactor as claimed in claim 1 wherein a line of peaks and troughs alternating across the foil extends perpendicular to the longitudinal axis of the foil.

### Claim 5 (depends on 1)

A reactor as claimed in claim 1 wherein a line of peaks and troughs alternating across the foil extends skew to the longitudinal axis of the foil.

### Claim 6 (depends on 1)

A reactor as claimed in claim 1 wherein the peaks and troughs are of triangular shape.

### Claim 7

A method for providing a reactor with a catalyst structure, wherein the reactor defines at least one first flow channel, and wherein each first flow channel is rectangular, having a width, the method comprising the steps of selecting a foil of a width selected in relation to the width of the first flow channel to provide enough clearance that the foil can be slid freely into the first flow channel, cutting a multiplicity of parallel slits in the foil, the slits extending in the length direction, and deforming the sections of foil between adjacent slits into peaks or troughs, so that the foil defines a multiplicity of peaks and troughs each with its axis extending across the foil, arranged such that peaks and troughs alternate across the width of the foil, providing the foil with a catalytic surface to form a catalyst structure, and then inserting the catalyst structure into the first flow channel.