Catalytic device with internal heat exchange

Abstract

The invention relates to a catalytic device with internal heat exchange that among other things can be used for vehicles with an internal combustion engine or for stationary engines where there is a certain amount of unburned gas components in the exhaust that can be converted in the catalyst. By the invention it is obtained that the maximum temperature in the catalyst is always nearly constant whatever the inlet temperature. Hereby, the catalyst can be designed to work at a very specific temperature, by which it is possible, partly to ensure a better and safer burnout of the unburned components, and partly to save expenses for catalyst materials. The exhaust gas is guided through the catalyst by at least three passage sections that have a mutual internal heat exchange. In the main reaction passage section there are catalytic materials of one or several kinds, in which the gas can react, and in which the gases heat exchange with the succeeding main heat transfer passage section passage.

1 - 50 . (canceled)  
   
   
       51 . Method for treatment of a fluid quantity including chemical reacting means such as combustible materials above a certain minimum quantity in a catalytic device, said method comprising: 
 entering said fluid quantity into the catalytic device through an inlet;    directing said fluid quantity through at least three mutually connected passage sections of said catalytic device in which said at least three passage sections include a main reaction passage section heat exchanging in counterflow with a main heat transfer passage section, wherein at least one section includes catalytic material of one or more kinds in which the catalytic material reacts with and/or enhances the reactions of said combustible materials, and wherein at least one of said at least three passage sections comprises a plurality of substantially parallel pipes;    heating or cooling said fluid quantity in said at least three passage sections by said internal heat exchange in said catalytic device between said sections; and    emitting the treated fluid quantity from the catalytic device through an outlet.    
   
   
       52 . Method according to  claim 51 , wherein a main reaction passage section heat exchanges with a main heat transfer passage section, and where the main reaction passage section heat exchanges with one or more preceding inlet passage sections and/or one or more succeeding outlet passage sections.  
   
   
       53 . Method according to  claim 51 , wherein the fluid quantity is directed through the succeeding passage sections in counterflow.  
   
   
       54 . Method according to  claim 51 , wherein further combustible material is added directly or indirectly to the catalytic device.  
   
   
       55 . Catalytic device for treatment of a fluid quantity including chemical reacting means such as combustible materials above a certain minimum quantity, said device comprising: 
 a container including at least one inlet and outlet for said fluid quantity;    said container further comprises at least three passage sections being mutually connected, where at least one section of said passage sections includes catalytic material of one or more kinds;    wherein the positioning of said passage sections forms at least one internal heat exchanger with mutual heat exchange between the sections;    wherein the at least three passage sections include a main reaction passage section which heat exchanges in counterflow with a main heat transfer passage section of said at least three passage sections; and    wherein at least one of said at least three passage sections comprises a plurality of substantially parallel pipes.    
   
   
       56 . Catalytic device according to  claim 55 , wherein said catalytic device comprises exactly three passage sections.  
   
   
       57 . Catalytic device according to  claim 55 , wherein the at least three sections comprises one or more inlet passage sections positioned above, alongside or outside said main reaction passage section.  
   
   
       58 . Catalytic device according to  claim 55 , wherein the at least three sections comprises one or more outlet passage sections positioned above, alongside or outside said main reaction passage section.  
   
   
       59 . Catalytic device according to  claim 55 , wherein said main reaction passage section is positioned above, alongside or outside said main heat transfer passage section.  
   
   
       60 . Catalytic device according to  claim 55 , wherein at least one of said main heat transfer passage section comprises one or more substantially parallel pipes.  
   
   
       61 . Catalytic device according to  claim 60 , wherein said main heat transfer passage section is integrated as a number of pipes in said main reaction passage section.  
   
   
       62 . Catalytic device according to  claim 60 , wherein said number of pipes is between 20 and 1000 pipes.  
   
   
       63 . Catalytic device according to  claim 60 , wherein said pipes form symmetrical patterns including at least one of triangular, quadrangular, similar patterns, and random patterns.  
   
   
       64 . Catalytic device according to  claim 60 , wherein said pipes are surrounded by catalytic material deposited on one or more carrier means.  
   
   
       65 . Catalytic device according to  claim 55 , wherein said pipes comprise at least one of a circular, an oval, a triangular, a four-sided, and any similar regular or irregular cross sectional shape.  
   
   
       66 . Catalytic device according to  claim 55 , wherein at least one of said three passage sections comprises one or more lamellar plates.  
   
   
       67 . Catalytic device according to  claim 66 , wherein said one or more lamellar plates form non-circular canals with a cross sectional shape formed by at least one of triangles, four sided shapes, combinations hereof, and similar shapes.  
   
   
       68 . Catalytic device according to  claim 66 , wherein indentations in a surface of said one ore more lamellar plates form longitudinal or diagonal patterns.  
   
   
       69 . Catalytic device according to  claim 55 , wherein said catalytic material is deposited on one ore more carrier means in at least one of said at least three passage sections.  
   
   
       70 . Catalytic device according to  claim 69 , wherein said one or more carrier means are composed of at least one of metal, ceramic, glass, other heat resistant materials, and combinations thereof.  
   
   
       71 . Catalytic device according to  claim 69 , wherein said one or more carrier means include a shape which is at least one of spherical, cylindrical, quadrangular, as saddle, ring, regular, and irregular.  
   
   
       72 . Catalytic device according to  claim 69 , wherein said one or more carrier means include a number of regular or irregular balls in layers across one of said passage sections, each layer being positioned perpendicularly between two adjacent pipes, and each of said layers comprising 2 to 6 balls.  
   
   
       73 . Catalytic device according to  claim 69 , wherein said one or more carrier means include monoliths or fibers.  
   
   
       74 . Catalytic device according to  claim 73 , wherein said fibers deposit with said catalytic material form a tangled bundle of fibres partly or totally filling one or more of said passage sections.  
   
   
       75 . Catalytic device according to  claim 73 , wherein said monoliths or fibers deposit with said catalytic material form longitudinal monoliths or fibres inside one or more of said passage sections.  
   
   
       76 . Catalytic device according to  claim 69 , wherein said main reaction passage section of said at least three passage sections comprises one or more kinds of said catalytic material deposit on said carrier means.  
   
   
       77 . Catalytic device according to  claim 69 , wherein one or more inlet and/or outlet passage sections of said at least three passage sections comprises one or more kinds of said catalytic material deposit on said carrier means.  
   
   
       78 . Catalytic device according to  claim 55 , wherein one or more of said at least three passage sections comprise combined carrier means including wall flow filters, fibres, balls and/or monoliths.  
   
   
       79 . Catalytic device according to  claim 78 , wherein said combined carrier means are positioned in continuation of each other through one or more of said at least three passages.  
   
   
       80 . Catalytic device according to  claim 55 , wherein said catalytic material includes metal or metal alloys from the Platinum metal group including Platinum (Pt), Palladium (Pl), Rhodium (Rh) and combinations hereof.  
   
   
       81 . Catalytic device according to  claim 55 , wherein said catalytic material includes metal oxides including at least one of Gold (Au), Platinum (Pt), Silver (Ag), Aluminum (Al), Lead (Pb), Zirconium (Zr), Copper (Cu), Cobalt (Co), Nickel (Ni), Iron (Fe), Cerium (Ce), Chrome (Cr), Tin (Sn), Manganese (Mn) and Rhodium (Rh), Oxides, and combinations hereof.  
   
   
       82 . Catalytic device according  claim 81 , wherein said catalytic material includes combinations of metal or metal alloys from the Platinum metal group and metal oxides.  
   
   
       83 . Catalytic device according to  claim 55 , wherein said main reaction passage section heat exchanges with said main heat transfer passage section of said at least three passage sections.  
   
   
       84 . Catalytic device according to  claim 83 , wherein said main reaction passage section heat exchanges with said main heat transfer passage section in counterflow.  
   
   
       85 . Catalytic device according to  claim 55 , wherein said main reaction passage section heat exchanges with one or more previous inlet and/or succeeding outlet passage sections.  
   
   
       86 . Catalytic device according to  claim 85 , wherein said main reaction passage section heat exchanges with said one or more inlet passage sections in counterflow.  
   
   
       87 . Catalytic-device according to  claim 85 , wherein said main reaction passage section heat exchanges with said one or more outlet passage sections in concurrent flow.  
   
   
       88 . Catalytic device according to  claim 55 , further comprising at least one layer of insulation between said at least three passage sections.  
   
   
       89 . Catalytic device according to  claim 88 , wherein said at least one layer of insulation is positioned between said main reaction passage section and one or more inlet passage sections of the at least three sections.  
   
   
       90 . Catalytic device according to  claim 55 , wherein a cross-sectional-area of said main reaction passage section is between 0.5 and 100 times a cross-sectional area of said main heat transfer passage section and/or inlet or outlet passage sections of the at least three sections are between 0.5 and 100 times the cross-sectional area of said main heat transfer passage section.  
   
   
       91 . Catalytic device according to  claim 55 , wherein a cross-sectional area of the main heat transfer passage section is between 0.5 and 10 times a cross-sectional area of the inlet of the catalytic device, said inlet being an exhaust pipe for a connected internal combustion engine.  
   
   
       92 . Catalytic device according to  claim 55 , wherein at least one of said passage sections comprises one or more wall flow filters with numerous porous walls allowing the fluid quantity to penetrate through the walls.  
   
   
       93 . Catalytic device according to  claim 55 , wherein further combustion material is added to the device through a fuel line connected to a fuel tank and a fuel supplying means or through adding further combustion material to the fluid quantity.  
   
   
       94 . Method according to  claim 51 , wherein the method cleans exhaust gas from an internal combustion engine.  
   
   
       95 . Method according to  claim 51 , wherein the method regulates or controls temperature in an exothermal or endothermal chemical reaction in an industrial chemical application.  
   
   
       96 . Method according to  claim 51 , wherein the method regulates or controls temperature in fuel cells.  
   
   
       97 . Catalytic device according to  claim 55 , wherein the device is disposed in connection with combustion engines in vehicles fuelled by at least one of petrol, diesel, natural gas, bottled gas, and similar fuels.  
   
   
       98 . Catalytic device according to  claim 55 , wherein the device is disposed in connection with stationary combustion engines fuelled by at least one of petrol, diesel, natural gas, bottled gas, and similar fuels.  
   
   
       99 . Catalytic device according to  claim 55 , wherein the device is disposed in connection with an exothermal or endothermal chemical reaction in an industrial chemical application.  
   
   
       100 . Catalytic device according to  claim 55 , wherein disposed in connection with fuel cells to regulate or control temperature.  
   
   
       101 . Catalytic device according to  claim 78 , wherein approximately one-third of the combined carrier means comprise said wall flow filters and a remainder of the combined carrier means comprise said fibers, balls and/or monoliths.