Catalytic reformer with upstream and downstream supports, and method of assembling same

Abstract

Engineers have attempted to reduce undesirable emissions from internal combustion engines by using apparatuses, such as catalytic reformers that include pre-combustion catalysts. An apparatus of the present invention includes an apparatus housing that defines at least a first flow inlet and includes an upstream support and a downstream support. The upstream support defines a plurality of second flow inlets, and the downstream support defines a first portion and a second portion of a plurality of outlets. A plurality of second flow paths are defined by a plurality of tubes extending between the plurality of second flow inlets and the second portion of the plurality of outlets. At least one first flow path is defined by a plurality of surfaces and fluidly connects the first flow inlet with the first portion of the plurality of outlets. At least one surface of the plurality of surfaces is coated with a pre-combustion catalyst. The downstream support preferably includes a plate with a predetermined porosity.

1 . An apparatus comprising: 
 an apparatus housing defining at least one first flow inlet, and including an upstream support that defines a plurality of second flow inlets and a downstream support that defines a plurality of outlets including a first portion and a second portion;    a plurality of surfaces defining at least one first flow path fluidly connecting the at least one first flow inlet to the first portion of the plurality of outlets, and at least one of the plurality of surfaces being coated with a pre-combustion catalyst; and    a plurality of tubes extending between the plurality of second flow inlets and the second portion of the plurality of outlets, and defining a plurality of second flow paths.    
   
   
       2 . The apparatus of  claim 1  wherein the apparatus housing includes a circumferencial housing being attached to the upstream support and the downstream support and defining the at least one first flow inlet.  
   
   
       3 . The apparatus of  claim 1  wherein the plurality of surfaces includes an outer surface of the plurality of tubes; and 
 the pre-combustion catalyst being coated on the outer surface of the plurality of tubes.    
   
   
       4 . The apparatus of  claim 1  wherein the downstream support includes a plate.  
   
   
       5 . The apparatus of  claim 4  wherein the downstream plate being comprised of powdered metal with a predetermined porosity.  
   
   
       6 . The apparatus of  claim 5  wherein the apparatus housing includes a circumferencial housing being attached to the upstream support and the downstream plate and defining the at least one first flow inlet; and 
 the pre-combustion catalyst being coated on an outer surface of the plurality of tubes.    
   
   
       7 . A gas turbine engine comprising: 
 an engine housing; and    the apparatus of  claim 1  attached to the engine housing.    
   
   
       8 . An apparatus comprising: 
 means for securing a plurality of tubes extending between an upstream support and a downstream support of an apparatus housing;    means for introducing an air flow outside the plurality of tubes via at least one first flow inlet defined by the apparatus housing;    means for introducing a fuel-air mixture flow within the plurality of tubes via a plurality of second flow inlets defined by the upstream support;    means for contacting the fuel-air mixture flow with a pre-combustion catalyst; and    means for delivering the air flow and the fuel-air mixture flow to a mixing chamber via a plurality of outlets defined by the downstream support.    
   
   
       9 . The apparatus of  claim 8  wherein the downstream support includes a plate.  
   
   
       10 . The apparatus of  claim 9  wherein the downstream plate being comprised of powdered metal with a predetermined porosity.  
   
   
       11 . The apparatus of  claim 10  wherein the apparatus housing includes a circumferencial housing attached to the upstream support and the downstream plate, and defining the at least one first flow inlet.  
   
   
       12 . The apparatus of  claim 11  wherein the plurality of surfaces includes an outer surface of the plurality of tubes; and 
 the pre-combustion catalyst being coated on the outer surface of the plurality of tubes.    
   
   
       13 . A gas turbine engine comprising: 
 an engine housing; and    the apparatus of  claim 8  attached to the engine housing.    
   
   
       14 . A method of assembling an apparatus comprising the steps of: 
 forming at least one first flow path and a plurality of second flow paths through an apparatus housing, at least in part, by attaching a first end of a plurality of tubes to a plurality of second flow inlets defined by an upstream support and a second end of the plurality of tubes to a portion of a plurality of second flow outlets defined by a downstream support; and    coating at least one surface of the first flow path with a pre-combustion catalyst.    
   
   
       15 . The method of  claim 14  wherein the method of forming includes a step of manufacturing at least the downstream support from powdered metal with a predetermined porosity.  
   
   
       16 . The method of  claim 14  wherein the step of forming includes a step of brazing the first end and the second end of the plurality of tubes to the upstream support and the downstream support, respectively.  
   
   
       17 . The method of  claim 14  wherein the step of forming includes a step of attaching a circumferencial housing to the upstream support and the downstream support.  
   
   
       18 . The method of  claim 14  wherein the step of coating includes a step of coating an outer surface of the plurality of tubes with the pre-combustion catalyst.