Combined hydrocarbon/ozone converter for airplane bleed air system

Abstract

The present invention provides a method and system for combined conversion of ozone and organic compounds in airplane bleed air. Catalytic converters have previously been used to reduce the levels of ozone in airplane bleed air. However, these converters have not yet provided an efficient system and method for effectively and simultaneously removing both ozone and organic compounds (including hydrocarbons). The present invention accomplishes the goals of removing both harmful substances by providing a washcoat on a single anodized surface layer, wherein the washcoat may contain an active metal oxide which is active for ozone conversion and may be impregnated with an active metal which is active for hydrocarbon and carbon monoxide conversion. Thus, a single system is disclosed that destroys both ozone and hydrocarbons.

We claim:  
     
         1 . An ozone and hydrocarbon destroying system, comprising; 
 a core;    an active metal oxide washcoat applied to said core that destroys ozone; and    an active metal impregnated in said active metal oxide washcoat that destroys hydrocarbons.    
     
     
         2 . The system as in  claim 1 , wherein said active metal impregnated in said active metal oxide washcoat destroys carbon monoxide.  
     
     
         3 . The system as in  claim 1 , where the washcoat and impregnated metals are applied to a heat exchanger such as a pre-cooler.  
     
     
         4 . The system as in  claim 1 , wherein said active metal oxide washcoat contains an oxide of a metal selected from the group consisting of manganese, palladium, copper, silver, iron, cobalt, and nickel, or any combination thereof.  
     
     
         5 . The system as in  claim 1 , wherein said active metal impregnated in said active metal oxide is a metal selected from the group consisting of platinum, iridium, gold, rhodium, manganese, copper, iron, nickel, or any combination thereof.  
     
     
         6 . The system as in  claim 1 , further comprising a surface treatment of said core consisting of mechanical, chemical, electrochemical, or thermal means, or a combination thereof.  
     
     
         7 . The system as in  claim 1 , wherein said washcoat is applied to said surface treated layer.  
     
     
         8 . The system as in  claim 1 , wherein said active metal impregnated in said active metal oxide is also impregnated in said surface-treated layer.  
     
     
         9 . The system as in  claim 1 , wherein said core is made of aluminum and the surface treatment includes formation of an anodized layer.  
     
     
         10 . The system as in  claim 1 , wherein said washcoat has a surface area of at least 20 m 2 /g.  
     
     
         11 . The system as in  claim 1 , wherein said core is a metal core comprised of a plurality of fins.  
     
     
         12 . An ozone and hydrocarbon destroying system, comprising; 
 a metal core;    a surface layer formed by physical, chemical, electrochemical, or thermal means from a portion of the core;    an active metal oxide washcoat that destroys ozone and containing manganese oxide or cobalt oxide applied to said surface layer to form a treated surface layer; and    an impregnated active metal impregnated in said active metal oxide washcoat that destroys hydrocarbons, wherein said impregnated active metal is platinum.    
     
     
         13 . The system as in  claim 12 , wherein said impregnated active metal in said active metal oxide washcoat destroys carbon monoxide.  
     
     
         14 . The system as in  claim 12 , wherein said washcoat and impregnated metals are applied to a heat exchanger such as a pre-cooler.  
     
     
         15 . The system as in  claim 12 , wherein said platinum is loaded at 0.5-15% by weight of said washcoat.  
     
     
         16 . The system as in  claim 12 , wherein said system destroys ozone, hydrocarbons, and carbon monoxide from bleed air at a flow between 1 and 250 lbs air flow/min.  
     
     
         17 . The system as in  claim 12 , wherein said system destroys ozone, hydrocarbons, and carbon monoxide from bleed air at a pressure between 10 and 50 psia.  
     
     
         18 . The system as in  claim 12 , wherein said washcoat is applied to said treated surface layer and said impregnated active metal also impregnates said treated surface layer.  
     
     
         19 . The system as in  claim 12 , wherein said surface layer is an anodized layer.  
     
     
         20 . The system as in  claim 12 , wherein said anodized surface layer is an aluminum oxide.  
     
     
         21 . The system as in  claim 12 , wherein said washcoat layer has a surface area of at least 20 m 2 /g.  
     
     
         22 . The system as in  claim 12 , wherein said core is a metal core comprised of a plurality of fins.  
     
     
         23 . An ozone and hydrocarbon destroying system for an environmental control system, comprising; 
 a metal core with a plurality of fins;    an anodized surface layer formed from a portion of the core, wherein said anodized surface layer is aluminum oxide;    an active metal oxide washcoat containing manganese oxide or cobalt oxide that applied to said anodized surface layer destroys ozone; and    an active metal impregnated in said active metal oxide washcoat that destroys hydrocarbons, wherein said active impregnated metal is platinum and wherein said platinum is loaded at 0.5-15% by weight of said washcoat.    
     
     
         24 . The system as in  claim 23 , wherein said active metal impregnated in said active metal oxide washcoat destroys carbon monoxide.  
     
     
         25 . The system as in  claim 23 , where the washcoat and impregnated metals are applied to a heat exchanger such as a pre-cooler.  
     
     
         26 . The system as in  claim 23 , wherein said system destroys ozone, hydrocarbons, and carbon monoxide from airplane bleed air at a flow between 1 and 250 lbs air flow/min.  
     
     
         27 . The system as in  claim 23 , wherein said system destroys ozone, hydrocarbons, and carbon monoxide from airplane bleed air at a pressure between 10 and 50 psia.  
     
     
         28 . The system as in  claim 23 , wherein said washcoat forms a washcoat layer that has a surface area of at least 20 m 2 /g.  
     
     
         29 . An ozone and hydrocarbon destroying system, comprising; 
 a core;    a high surface area refractory metal oxide washcoat applied to said core;    a first active metal impregnated in said washcoat layer that destroys ozone; and    a second active metal impregnated in said washcoat layer that destroys hydrocarbons and carbon monoxide .    
     
     
         30 . The system as in  claim 29 , wherein said second active metal impregnated in said washcoat layer destroys carbon monoxide.  
     
     
         31 . The system as in  claim 29 , where the washcoat and impregnated metals are applied to a heat exchanger such as a pre-cooler.  
     
     
         32 . The system as in  claim 29 , wherein said first active metal washcoat contains a metal or metal oxide selected from the group consisting of manganese, palladium, copper, silver, iron, cobalt, and nickel, or any combination thereof.  
     
     
         33 . The system as in  claim 29 , wherein said second active metal is a metal or metal oxide selected from the group consisting of platinum, iridium, gold, rhodium, manganese, copper, iron, nickel, or any combination thereof.  
     
     
         34 . The system as in  claim 29 , wherein said core is metal and further comprising a surface treatment of said core consisting of mechanical, chemical, electrochemical, or thermal means, or a combination thereof.  
     
     
         35 . The system as in  claim 29 , wherein said core is made of aluminum and said surface treatment includes formation of an anodized layer.  
     
     
         36 . The system as in  claim 29 , wherein said first active metal is also impregnated in said surface-treated layer.  
     
     
         37 . The system as in  claim 29 , wherein said second active metal is also impregnated in said surface-treated layer.  
     
     
         38 . The system as in  claim 29 , wherein said washcoat layer has a surface area of at least 20 m 2 /g.  
     
     
         39 . The system as in  claim 29 , wherein said core is a metal core comprised of a plurality of fins.  
     
     
         40 . An ozone and hydrocarbon destroying system, comprising; 
 a metal core;    a surface layer formed by physical, chemical, electrochemical, or thermal means from a portion of the core;    a high surface area refractory metal oxide washcoat that is applied to said surface layer    a first active metal that impregnated into said washcoat destroys ozone, wherein said first active metal is manganese or cobalt; and    a second active metal impregnated into said washcoat which destroys hydrocarbons, wherein said second active material is platinum.    
     
     
         41 . The system as in  claim 40 , wherein said second active metal impregnated in said washcoat destroys carbon monoxide.  
     
     
         42 . The system as in  claim 40 , wherein said washcoat and impregnated metals are applied to a heat exchanger such as a pre-cooler.  
     
     
         43 . The system as in  claim 40 , wherein said manganese or cobalt is loaded at up to 100% by weight of said washcoat.  
     
     
         44 . The system as in  claim 40 , wherein said platinum is loaded at 0.5-15% by weight of said washcoat.  
     
     
         45 . The system as in  claim 40 , wherein said system destroys ozone, hydrocarbons,-and carbon monoxide from airplane bleed air at a flow between 1 and 250 lbs air flow/min.  
     
     
         46 . The system as in  claim 40 , wherein said system destroys ozone, hydrocarbons, and carbon monoxide from airplane bleed air at a pressure between 10 and 50 psia.  
     
     
         47 . The system as in  claim 40 , wherein said first active metal and second active metal are also impregnated in said surface layer.  
     
     
         48 . The system as in  claim 40 , wherein said surface layer is an anodized surface layer.  
     
     
         49 . The system as in  claim 40 , wherein said anodized layer is an aluminum oxide.  
     
     
         50 . The system as in  claim 40 , wherein said washcoat layer has a surface area of at least 20 m 2 /g.  
     
     
         51 . The system as in  claim 40 , wherein said core is a metal core comprised of a plurality of fins.  
     
     
         52 . An ozone and hydrocarbon destroying system for an environmental control system of an aircraft, comprising; 
 a metal core with a plurality of fins;    an anodized surface layer formed from a portion of said core, wherein said anodized surface layer is aluminum oxide;    a high surface area refractory metal oxide washcoat applied to said anodized surface layer;    a first active metal that impregnated into said washcoat destroys ozone, wherein said first active metal is cobalt oxide and is loaded at up to 100% by weight of said washcoat; and    and a second active metal impregnated in said washcoat destroys hydrocarbons, wherein said second active metal is platinum and is loaded at 0.5-15% by weight of said washcoat.    
     
     
         53 . The system as in  claim 52 , wherein said second active metal impregnated in said washcoat destroys carbon monoxide.  
     
     
         54 . The system as in  claim 52 , where the washcoat and impregnated metals are applied to a heat exchanger such as a pre-cooler.  
     
     
         55 . The system as in  claim 52 , wherein said system destroys ozone, hydrocarbons, and carbon monoxide from airplane bleed air at a flow between 1 and 250 lbs air flow/min.  
     
     
         56 . The system as in  claim 52 , wherein said system destroys ozone, hydrocarbons, and carbon monoxide from airplane bleed air at a pressure between 10 and 50 psia.  
     
     
         57 . The system as in  claim 52 , wherein said washcoat layer has a surface area of at least 20 m 2 /g.  
     
     
         58 . A method of preparing a core of a catalytic converter so as to provide simultaneous hydrocarbon and ozone destruction, comprising; 
 applying to said core an active metal oxide washcoat that has a high efficiency for the removal of ozone; and    impregnating said washcoat with an active metal, wherein said active metal has a high efficiency for the conversion of hydrocarbons to carbon dioxide and water.    
     
     
         59 . The method as in  claim 58 , wherein said washcoat has a surface area of at least 20 m 2 /g.  
     
     
         60 . The method as in  claim 58 , wherein said active metal oxide washcoat contains an oxide of a metal selected from the group consisting of manganese, cobalt, palladium, copper, silver, iron, and nickel, or any combination thereof.  
     
     
         61 . The method as in  claim 58 , wherein said impregnated active metal is selected from the group consisting of platinum, iridium, gold, rhodium, manganese, copper, iron, nickel, or any combination thereof.  
     
     
         62 . The method as in  claim 58 , wherein said active metal oxide washcoat is created by: 
 forming a slurry of an organosiloxane resin in monomeric or polymeric form and an oxide of a metal selected from the group consisting of manganese, cobalt, palladium, copper, silver, iron, and nickel, or any combination thereof    applying said slurry to said core; and    drying and calcining said washcoated core.    
     
     
         63 . The method as in  claim 58 , wherein said active metal oxide washcoat is created by: 
 forming a slurry of an organosiloxane resin in monomeric or polymeric form and a combination of a refractory metal oxide and an oxide or salt of metal selected from the group consisting of manganese, cobalt, palladium, copper, silver, iron, and nickel, or any combination thereof;    applying said slurry to said core; and    drying and calcining said washcoated core.    
     
     
         64 . The method as in  claim 58 , wherein said core is metallic, and further comprising the step of treating surface of said core by mechanical, chemical, electrochemical, or thermal means prior to applying said washcoat.  
     
     
         65 . The method as in  claim 58 , where the treatment comprises the step of anodizing a surface portion.  
     
     
         66 . A method of preparing a core of a catalytic converter so as to provide a combined hydrocarbon-destroying and ozone-destroying converter, comprising: 
 applying to said core of said catalytic converter a washcoat, wherein said washcoat contains a high-surface area refractory metal oxide;    drying and calcining washcoated core;    impregnating said washcoated core with a salt of a first active metal and a salt of a second active metal; and    drying and calcining said impregnated and washcoated core.    
     
     
         67 . The method as in  claim 66 , wherein said high-surface area refractory metal oxide is selected from the group consisting of alumina, titania, silica, zirconia, or any combination thereof.  
     
     
         68 . The method as in  claim 66 , wherein said first active metal is selected from the group consisting of manganese, cobalt, palladium, copper, silver, iron, and nickel, or any combination thereof.  
     
     
         69 . The method as in  claim 66 , wherein said second active metal is selected from the group consisting of platinum, iridium, gold, rhodium, manganese, copper, iron, nickel, or any combination thereof.  
     
     
         70 . The method as in  claim 66 , wherein said salt of said first active metal and said salt of said second active metal are simultaneously impregnated into said washcoat, dried, and calcined.  
     
     
         71 . The method as in  claim 66 , wherein said salt of said first active metal is impregnated into said washcoat, dried, and calcined, then said salt of said second active metal is impregnated into said washcoat, dried, and calcined.  
     
     
         72 . The method as in  claim 66 , wherein said core is metallic and treated by mechanical, chemical, electrochemical, or thermal means before applying said washcoat.  
     
     
         73 . The method as in  claim 66 , wherein said core is aluminum and said mechanical, chemical, electrochemical, or thermal means includes anodization.  
     
     
         74 . The method as in  claim 66 , further comprising the step of forming an aluminum oxide on said core.  
     
     
         75 . A method of simultaneously destroying ozone, hydrocarbons, and carbon monoxide in airplane bleed air, comprising; 
 passing ozone, hydrocarbons, and carbon monoxide containing air through a catalytic converter, wherein said catalytic converter includes: 
 a core;  
 a washcoat on said core that contains an first active metal that has a high efficiency for the removal of ozone; and  
 said washcoat having a second active metal, wherein said second active metal has a high efficiency for the conversion of hydrocarbons to carbon dioxide and water.  
   
     
     
         76 . A method as in  claim 75 , wherein said core is chosen from the group consisting of a ceramic monolith, a metal monolith composed of straight channels, a metal core composed of a plurality of fins enclosed by a shell, or layers of fins stacked in an alternating manner to form a heat exchanger.