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Title: Revolutionary systems for catalytic combustion and diesel catalytic particulate traps.

Abstract

This report is a summary of an LDRD project completed for the development of materials and structures conducive to advancing the state of the art for catalyst supports and diesel particulate traps. An ancillary development for bio-medical bone scaffolding was also realized. Traditionally, a low-pressure drop catalyst support, such as a ceramic honeycomb monolith, is used for catalytic reactions that require high flow rates of gases at high-temperatures. A drawback to the traditional honeycomb monoliths under these operating conditions is poor mass transfer to the catalyst surface in the straight-through channels. ''Robocasting'' is a unique process developed at Sandia National Laboratories that can be used to manufacture ceramic monoliths with alternative 3-dimensional geometries, providing tortuous pathways to increase mass transfer while maintaining low-pressure drops. These alternative 3-dimensional geometries may also provide a foundation for the development of self-regenerating supports capable of trapping and combusting soot particles from a diesel engine exhaust stream. This report describes the structures developed and characterizes the improved catalytic performance that can result. The results show that, relative to honeycomb monolith supports, considerable improvement in mass transfer efficiency is observed for robocast samples synthesized using an FCC-like geometry of alternating rods. Also, there is clearly amore » trade-off between enhanced mass transfer and increased pressure drop, which can be optimized depending on the particular demands of a given application. Practical applications include the combustion of natural gas for power generation, production of syngas, and hydrogen reforming reactions. The robocast lattice structures also show practicality for diesel particulate trapping. Preliminary results for trapping efficiency are reported as well as the development of electrically resistive lattices that can regenerate the structure by combusting the trapped soot. During this project an ancillary bio-medical application was discovered for lattices of hydroxyapatite. These structures show promise as bone scaffolds for the reparation of damaged bone. A case study depicting the manufacture of a customized device that fits into a damaged mandible is described.« less

Authors:
; ; ;
Publication Date:
Research Org.:
Sandia National Laboratories (SNL), Albuquerque, NM, and Livermore, CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
920793
Report Number(s):
SAND2004-6443
TRN: US200803%%108
DOE Contract Number:  
AC04-94AL85000
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
03 NATURAL GAS; 08 HYDROGEN; 33 ADVANCED PROPULSION SYSTEMS; CATALYST SUPPORTS; CATALYSTS; CERAMICS; COMBUSTION; DIESEL ENGINES; EFFICIENCY; FLOW RATE; GASES; GEOMETRY; HYDROGEN; MASS TRANSFER; NATURAL GAS; PARTICULATES; POWER GENERATION; PRESSURE DROP; SOOT; TRAPPING; Ceramic materials.; Catalyst supports.; Mass transfer-Experiments.

Citation Formats

Stuecker, John Nicholas, Witze, Peter O, Ferrizz, Robert Matthew, Cesarano, Joseph, III, and Miller, James Edward. Revolutionary systems for catalytic combustion and diesel catalytic particulate traps.. United States: N. p., 2004. Web. doi:10.2172/920793.
Stuecker, John Nicholas, Witze, Peter O, Ferrizz, Robert Matthew, Cesarano, Joseph, III, & Miller, James Edward. Revolutionary systems for catalytic combustion and diesel catalytic particulate traps.. United States. https://doi.org/10.2172/920793
Stuecker, John Nicholas, Witze, Peter O, Ferrizz, Robert Matthew, Cesarano, Joseph, III, and Miller, James Edward. 2004. "Revolutionary systems for catalytic combustion and diesel catalytic particulate traps.". United States. https://doi.org/10.2172/920793. https://www.osti.gov/servlets/purl/920793.
@article{osti_920793,
title = {Revolutionary systems for catalytic combustion and diesel catalytic particulate traps.},
author = {Stuecker, John Nicholas and Witze, Peter O and Ferrizz, Robert Matthew and Cesarano, Joseph, III and Miller, James Edward},
abstractNote = {This report is a summary of an LDRD project completed for the development of materials and structures conducive to advancing the state of the art for catalyst supports and diesel particulate traps. An ancillary development for bio-medical bone scaffolding was also realized. Traditionally, a low-pressure drop catalyst support, such as a ceramic honeycomb monolith, is used for catalytic reactions that require high flow rates of gases at high-temperatures. A drawback to the traditional honeycomb monoliths under these operating conditions is poor mass transfer to the catalyst surface in the straight-through channels. ''Robocasting'' is a unique process developed at Sandia National Laboratories that can be used to manufacture ceramic monoliths with alternative 3-dimensional geometries, providing tortuous pathways to increase mass transfer while maintaining low-pressure drops. These alternative 3-dimensional geometries may also provide a foundation for the development of self-regenerating supports capable of trapping and combusting soot particles from a diesel engine exhaust stream. This report describes the structures developed and characterizes the improved catalytic performance that can result. The results show that, relative to honeycomb monolith supports, considerable improvement in mass transfer efficiency is observed for robocast samples synthesized using an FCC-like geometry of alternating rods. Also, there is clearly a trade-off between enhanced mass transfer and increased pressure drop, which can be optimized depending on the particular demands of a given application. Practical applications include the combustion of natural gas for power generation, production of syngas, and hydrogen reforming reactions. The robocast lattice structures also show practicality for diesel particulate trapping. Preliminary results for trapping efficiency are reported as well as the development of electrically resistive lattices that can regenerate the structure by combusting the trapped soot. During this project an ancillary bio-medical application was discovered for lattices of hydroxyapatite. These structures show promise as bone scaffolds for the reparation of damaged bone. A case study depicting the manufacture of a customized device that fits into a damaged mandible is described.},
doi = {10.2172/920793},
url = {https://www.osti.gov/biblio/920793}, journal = {},
number = ,
volume = ,
place = {United States},
year = {Wed Dec 01 00:00:00 EST 2004},
month = {Wed Dec 01 00:00:00 EST 2004}
}