Catalytic burner

Abstract

A catalytic burner includes a porous diffuser member and a porous distributor member. At least one seal extends between the porous diffuser member and the porous distributor member thereby defining an oxidation chamber. Catalyst media particles for catalyzing an oxidation reaction of a fuel stream to produce heat and an exhaust stream is disposed within the oxidation chamber. The catalyst media particles comprise carrier particles. The carrier particles comprise refractory material, and at least some of the carrier particles have thereon an outer coating comprising an oxidation catalyst. The catalyst media particles have a void fraction of at least 0.6.

1 . A catalytic burner comprising:
 a porous diffuser member;   a porous distributor member;   at least one seal extending between the porous diffuser member and the porous distributor member, thereby defining an oxidation chamber; and   catalyst media particles for catalyzing an oxidation reaction of a fuel stream to produce heat and an exhaust stream, wherein the catalyst media particles is disposed within the oxidation chamber, wherein the catalyst media particles comprise carrier particles, each carrier particle comprising refractory material, wherein at least some of the carrier particles have thereon an outer coating comprising an oxidation catalyst, and wherein the catalyst media particles have a void fraction of at least 0.6.   
     
     
         2 . The catalytic burner of  claim 1 , wherein the porous diffuser member comprises a first open end, wherein the porous distributor member is disposed at least partially inside the porous diffuser member, wherein the porous distributor member comprises a second open end. 
     
     
         3 . The catalytic burner of  claim 1 , further comprising a first end cap, wherein the porous diffuser member further comprises a third open end, and wherein the first end cap covers the first open end. 
     
     
         4 . The catalytic burner of  claim 3 , further comprising a second end cap, wherein:
 the first end cap comprises an alignment pin inwardly extending therefrom along a longitudinal axis of the porous distributor member;   the porous distributor member further comprises a fourth open end; and   the second end cap covers the fourth open end, except for a central opening in the second end cap adapted to receive the alignment pin.   
     
     
         5 . The catalytic burner of  claim 3 , wherein the porous diffuser member comprises at least one of a cylindrical conduit or a frustoconical conduit. 
     
     
         6 . The catalytic burner of  claim 1 , wherein the outer coating is discontinuous. 
     
     
         7 . The catalytic burner of  claim 1 , wherein the void fraction is at least 0.65. 
     
     
         8 . The catalytic burner of  claim 1 , wherein the porous distributor member and the porous diffuser member are separated from each other by an average distance of from 1 to 6 millimeters. 
     
     
         9 . The catalytic burner of  claim 1 , wherein the catalyst media particles have an average particle diameter of from 0.5 millimeter to 3 millimeters. 
     
     
         10 . The catalytic burner of  claim 1 , wherein the carrier particles are saddle-shaped. 
     
     
         11 . The catalytic burner of  claim 1 , wherein the carrier particles have a substantially constant cross-sectional profile along their length. 
     
     
         12 . The catalytic burner of  claim 1 , wherein the oxidation catalyst comprises palladium. 
     
     
         13 . The catalytic burner of  claim 12 , wherein the palladium is deposited by physical vapor deposition. 
     
     
         14 . The catalytic burner of  claim 1 , wherein the outer coating comprises an inner layer comprising cerium oxide in contact with the carrier particle and supporting an outer layer comprising the oxidation catalyst.