US5326253A
Expired / Lapsed
US
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Partial combustion process and a catalyst structure for use in the process
Assignee: International Engine Intellectual Property Co LLC
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Filing: 1990-11-26
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Granted: 1994-07-05
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Expires: 2010-11-26
Abstract
Abstract This invention is both a partial combustion process in which the fuel is partially combusted using specific catalysts and catalytic structures and also a catalyst structure for use in the process. The choice of catalysts and supports solves problems in the art dealing with the stability of the overall catalyst structure and ease of catalyst operation. The catalyst structure is stable due to its comparatively low operating temperature, has a low temperature at which catalytic combustion begins, and yet is not susceptible to temperature "runaway". The combustion gas produced by the catalytic process typically is below the autocombustive temperature for the gas mixture; the gas may be used at that temperature, or fed to other combustion stages for ultimate use in a gas turbine, furnace, boiler, or the like.
Inventors
- 👤 Ralph A. Dalla Betta
- 👤 Toru Shoji
- 👤 Kazunori Tsurumi
- 👤 Nobuyasu Ezawa
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 03:48
CPC Classifications
B; B01; B01D; B01D53/00; B01D53/34; B01D53/74; B01D53/86; B01D53/8621; B01D53/8625; B01D53/8628; B01J; B01J23/00; B01J23/38; B01J23/40; B01J23/44; B01J37/00; B01J37/02; B01J37/0215; B01J37/0225
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
111 words
A partial combustion process comprising the steps of: a. mixing an amount of an oxygen-containing gas with a combustible fuel to produce a combustible gas mixture, and b. passing the combustible gas mixture into a combustion zone comprising palladium catalyst on at least a portion of a catalyst support having passageways for the passage and partial combustion of the combustible gas mixture and where the palladium catalyst is at least partially covered by a diffusion barrier to produce a partially combusted exhaust gas having a bulk temperature less than the adiabatic combustible temperature of the combustible gas mixture and a catalyst temperature less than the TGA temperature for the palladium catalyst.
Claim 2
Dependent Claim
111 words
A partial combustion process comprising the steps of: a. mixing an amount of an oxygen-containing gas with a combustible fuel to produce a combustible gas mixture, and b. passing the combustible gas mixture into a combustion zone comprising palladium catalyst on at least a portion of a catalyst support having passageways for the passage and partial combustion of the combustible gas mixture and where the palladium catalyst is at least partially covered by a diffusion barrier to produce a partially combusted exhaust gas having a bulk temperature less than the adiabatic combustible temperature of the combustible gas mixture and a catalyst temperature less than the TGA temperature for the palladium catalyst.
Claim 3
Dependent Claim
25 words
The process of claim 1 where the catalyst support comprises a material selected from the group of metal and a metal having an oxide coating.
Claim 4
Dependent Claim
13 words
The process of claim 2 where the catalyst support comprises a ferrous alloy.
Claim 5
Dependent Claim
29 words
The process of claim 3 where the catalyst support comprises a ferrous alloy coated by zirconia, titania, silica, alumina, a non-catalytic oxide, a refractory metal oxide, or mixtures thereof.
Claim 6
Dependent Claim
27 words
The process of claim 1 where the palladium catalyst additionally comprises one or more adjunct catalyst metals selected from silver, gold, platinum, ruthenium, rhodium, iridium, or osmium.
Claim 7
Dependent Claim
13 words
The process of claim 5 where the adjunct catalyst is silver or platinum.
Claim 8
Dependent Claim
11 words
The process of claim 1 where the diffusion barrier comprises alumina.
Claim 9
Dependent Claim
11 words
The process of claim 1 where the diffusion barrier comprises zirconia.
Claim 10
Dependent Claim
13 words
The process of claim 1 where the diffusion barrier layer is a washcoat.
Claim 11
Dependent Claim
21 words
The process of claim 1 where the combustible fuel is selected from liquid fuels, gaseous fuels, oxygen containing fuels, and mixtures.
Claim 12
Dependent Claim
14 words
The process of claim 10 where the liquid fuels are selected from vaporizable fuels.
Claim 13
Dependent Claim
22 words
The process of claim 10 where the gaseous fuels are selected from the group consisting of methane, ethane, ethylene, propane, and propylene.
Claim 14
Dependent Claim
18 words
The process of claim 10 where the oxygen-containing fuels comprise C 1 -C 5 alcohols, ethers, or mixtures.
Claim 15
Dependent Claim
32 words
The process of claim 1 where the combustible gas comprises methane and the combustible gas mixture is passed into the partial combustion zone at a temperature of at least approximately 325° C.
Claim 16
Dependent Claim
20 words
The process of claim 14 where the partial combustion zone has a gauge pressure between -0.25 atm and 35 atm.
Claim 17
Dependent Claim
16 words
The process of claim 14 where the gauge pressure is between zero atm and 17 atm.
Claim 18
Dependent Claim
23 words
The process of claim 2 where the catalyst support having longitudinal passageways is in the form of a honeycomb, tubes, or rolled corrugation.
Claim 19
Dependent Claim
16 words
The process of claim 17 where only a portion of the longitudinal passageway surfaces contain palladium.
Claim 20
Dependent Claim
35 words
The process of claim 18 where the portion of the longitudinal passageways surfaces containing palladium are adjacent to passageway surfaces not containing palladium and those surfaces are in integral heat exchange relationship to each other.
Claim 21
Dependent Claim
24 words
The process of claim 1 where a portion of the catalyst support first contacting the combustible gas mixture comprises a higher activity palladium catalyst.
Claim 22
Dependent Claim
136 words
A partial combustion process comprising the steps of: a. mixing an amount of air and methane to produce a combustible gas mixture having an adiabatic combustion temperature substantially above 900° C., and b. passing the combustible gas mixture into a combustion zone containing a catalyst support of a spiral of corrugated ferrous alloy sheet having passageways for the passage and partial combustion of the combustible gas mixture and having a catalyst composition comprising a palladium catalyst in at least a portion of the passageways in said support and where the palladium catalyst is at least partially covered by a diffusion barrier, to produce a partially combusted exhaust gas having a bulk temperature less than the adiabatic combustible temperature of the combustible gas mixture and a catalyst temperature less than the TGA temperature of the palladium catalyst.
Claim 23
Dependent Claim
136 words
A partial combustion process comprising the steps of: a. mixing an amount of air and methane to produce a combustible gas mixture having an adiabatic combustion temperature substantially above 900° C., and b. passing the combustible gas mixture into a combustion zone containing a catalyst support of a spiral of corrugated ferrous alloy sheet having passageways for the passage and partial combustion of the combustible gas mixture and having a catalyst composition comprising a palladium catalyst in at least a portion of the passageways in said support and where the palladium catalyst is at least partially covered by a diffusion barrier, to produce a partially combusted exhaust gas having a bulk temperature less than the adiabatic combustible temperature of the combustible gas mixture and a catalyst temperature less than the TGA temperature of the palladium catalyst.
Claim 24
Dependent Claim
11 words
The process of claim 21 where the diffusion barrier comprises alumina.
Claim 25
Dependent Claim
11 words
The process of claim 21 where the diffusion barrier comprises zirconia.
Claim 26
Dependent Claim
15 words
The process of claim 23 where only a portion of the longitudinal passageways comprise palladium.
Claim 27
Dependent Claim
27 words
The process of claim 21 where the palladium catalyst additionally comprises one or more adjunct catalyst metals selected from silver, gold, platinum, ruthenium, rhodium, iridium, or osmium.
Claim 28
Dependent Claim
13 words
The process of claim 25 where the adjunct catalyst is silver or platinum.
Claim 29
Dependent Claim
28 words
The process of claim 21 where the combustible gas mixture is preheated to a temperature of more than approximately 325° C. prior to passage into the combustion zone.
Claim 30
Dependent Claim
18 words
The process of claim 21 where only a portion of the surfaces of the longitudinal passageways comprise palladium.
Claim 31
Dependent Claim
38 words
The process of claim 28 where the portion of the surfaces of the longitudinal passageway surfaces containing palladium are adjacent to passageway surfaces not containing palladium and those surfaces are in integral heat exchange relationship to each other.
Claim 32
Dependent Claim
24 words
The process of claim 21 where a portion of the catalyst support first contacting the combustible gas mixture comprises a higher activity palladium catalyst.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1997-07-04 | 1998-01-03 | 1998-07-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-07-04 | 2002-01-03 | 2002-07-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-07-04 | 2006-01-03 | 2006-07-05 | $7700.00 | Window Closed / Lapsed |