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Title: Free-standing monolithic catalyst with micro-scale channel dimensions

Abstract

A monolithic catalyst with micro-scale flow channels and methods of making such a monolithic catalyst are provided. The monolithic catalyst includes a plurality of thin catalyst walls. The walls have a set thickness in a range from 1 to 150 .mu.m. The thin catalyst walls define a plurality of flow channels. A fugitive material is used to form the flow channels. The flow channels have a set width in a range from 1 to 200 .mu.m. The flow channels are formed by an organic fugitive material, which burns off during processing. By using the thin catalyst walls and flow channels having a set width in a range from 1 to 200 .mu.m, a reduced diffusion path length that molecules travel between the bulk gas and the active site is provided. Accelerating the mass transport thus improves the overall reaction rate, which allows processing of more reactants. Thus, the volume of the required catalyst is reduced, allowing more compact reactors. Fabrication methods involve simple, low-cost and scaleable procedures, allowing the flow channel and catalyst dimensions to be easily scaled to a requisite size for a given application. One fabrication method involves tape casting successive layers of fugitive and catalyst materials, andmore » then firing to remove the organic binders and partially sinter the catalyst particles. The slurries can also be cast into thin layers using various processes, including screen printing, wet spraying and spin casting. Another fabrication method for fabricating a supported catalyst involves dipping a pre-shaped metal foil into a slurry containing an active catalyst powder, allowing the catalyst slurry to coat the foil evenly and allowing the catalyst slurry coated foil to dry. The catalyst slurry coated foil is dipped into a solution to form a fugitive coating layer, next the coated metal foil is cut into strips and formed into a selected shape.« less

Inventors:
; ; ;
Issue Date:
Research Org.:
Univ. of Chicago, IL (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1531465
Patent Number(s):
6670305
Application Number:
09/851,843
Assignee:
The University of Chicago (Chicago, IL)
Patent Classifications (CPCs):
Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02P - CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY
DOE Contract Number:  
W-31-109-ENG-38
Resource Type:
Patent
Resource Relation:
Patent File Date: 2001-05-09
Country of Publication:
United States
Language:
English
Subject:
30 DIRECT ENERGY CONVERSION

Citation Formats

Bae, Joong-Myeon, Carter, John David, Krumpelt, Michael, and Ahmed, Shabbir. Free-standing monolithic catalyst with micro-scale channel dimensions. United States: N. p., 2003. Web.
Bae, Joong-Myeon, Carter, John David, Krumpelt, Michael, & Ahmed, Shabbir. Free-standing monolithic catalyst with micro-scale channel dimensions. United States.
Bae, Joong-Myeon, Carter, John David, Krumpelt, Michael, and Ahmed, Shabbir. Tue . "Free-standing monolithic catalyst with micro-scale channel dimensions". United States. https://www.osti.gov/servlets/purl/1531465.
@article{osti_1531465,
title = {Free-standing monolithic catalyst with micro-scale channel dimensions},
author = {Bae, Joong-Myeon and Carter, John David and Krumpelt, Michael and Ahmed, Shabbir},
abstractNote = {A monolithic catalyst with micro-scale flow channels and methods of making such a monolithic catalyst are provided. The monolithic catalyst includes a plurality of thin catalyst walls. The walls have a set thickness in a range from 1 to 150 .mu.m. The thin catalyst walls define a plurality of flow channels. A fugitive material is used to form the flow channels. The flow channels have a set width in a range from 1 to 200 .mu.m. The flow channels are formed by an organic fugitive material, which burns off during processing. By using the thin catalyst walls and flow channels having a set width in a range from 1 to 200 .mu.m, a reduced diffusion path length that molecules travel between the bulk gas and the active site is provided. Accelerating the mass transport thus improves the overall reaction rate, which allows processing of more reactants. Thus, the volume of the required catalyst is reduced, allowing more compact reactors. Fabrication methods involve simple, low-cost and scaleable procedures, allowing the flow channel and catalyst dimensions to be easily scaled to a requisite size for a given application. One fabrication method involves tape casting successive layers of fugitive and catalyst materials, and then firing to remove the organic binders and partially sinter the catalyst particles. The slurries can also be cast into thin layers using various processes, including screen printing, wet spraying and spin casting. Another fabrication method for fabricating a supported catalyst involves dipping a pre-shaped metal foil into a slurry containing an active catalyst powder, allowing the catalyst slurry to coat the foil evenly and allowing the catalyst slurry coated foil to dry. The catalyst slurry coated foil is dipped into a solution to form a fugitive coating layer, next the coated metal foil is cut into strips and formed into a selected shape.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2003},
month = {12}
}

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Works referenced in this record:

Microcomponent sheet architecture
patent, March 1997


Compact and light weight catalyst bed for use in a fuel cell power plant and method for forming the same
patent, October 2000


Catalyst structure employing integral heat exchange
patent, April 1996


Exhaust gas purifying catalyst
patent, September 2002


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