Rapid activation catalyst system in a non-thermal plasma catalytic reactor
AssigneeGM Global Technology Operations LLC
InventorsGerald E. Voecks, Paul Taichiang Yu
Life of this patent
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Abstract
A rapid start reactor is provided that can be used, for example, in a water gas shift reactor of a fuel processor. A reactor has a catalyst support structure with one or more surfaces overlaid with an active coating that includes a catalyst. The active coating heats upon exposure to a non-thermal energy source. The reactor also includes a generator of non-thermal energy for applying non-thermal energy to the active coating. Methods for operating such a reactor during transient and/or start-up conditions are also provided.
Claims15
A reactor for rapid start-up, comprising:
- a catalyst support structure having a surface with one or more regions overlaid with an active coating comprising a catalyst, wherein said active coating heats upon exposure to a non-thermal energy source;
- and
- a generator of non-thermal energy for applying said non-thermal energy to said active coating,
- wherein said catalyst support structure is an open structured porous foam with a tortuous flow pattern that enhances non-thermal energy penetration and facilitates penetration of one or more reactants introduced to the reactor and said regions are located on a surface of said tortuous flow pattern,
- wherein said active coating further comprises an active material that heats upon exposure to said non-thermal energy source and said active coating comprises a first layer and a second layer, wherein said first layer comprises said active material and is disposed on said one or more regions of said surface of said catalyst support structure and said second layer comprises said catalyst and is disposed on said first layer with said first layer between said second layer and said support structure.
A method for operating a reactor during transient and/or start-up conditions comprising:
- providing a catalyst support structure having a surface with one or more regions overlaid with an active coating comprising a catalyst, wherein said active coating is capable of heating upon exposure to a non-thermal energy source;
- generating non-thermal energy for heating of said active coating with a non-thermal energy source generator;
- and
- heating said active coating to a temperature greater than or equal to an activation temperature of said catalyst,
- wherein said generating continues only until said active coating reaches a temperature equal to or greater than an activation temperature and said catalyst sustains reaction via thermal heat provided to, or generated within, the reactor.
A shift reactor comprising:
- a catalyst support structure having a surface with one or more regions overlaid with an active coating comprising a water gas shift catalyst, wherein said active coating heats to catalyst activation temperatures upon exposure to a non-thermal energy source;
- and
- a generator of non-thermal energy for applying said non-thermal energy to said active coating,
- wherein said active coating further comprises an active material that heats upon exposure to said non-thermal energy source and said active coating comprises a first layer and a second layer, wherein said first layer comprises said active material and is disposed on said one or more regions of said surface of said support structure and said second layer comprises said catalyst and is disposed on said first layer with said first layer between said second layer and said support structure.
Dependencies are inferred from the claim text.