High-efficiency catalytic converters for treating exhaust gases

Abstract

Several embodiments of high-efficiency catalytic converters and associated systems and methods are disclosed. In one embodiment, a catalytic converter for treating a flow of exhaust gas comprising a reaction chamber, a heating enclosure enclosing at least a portion of the reaction chamber, and an optional coolant channel encasing the heating enclosure. The reaction chamber can have a first end section through which the exhaust gas flows into the reaction chamber and a second end section from which the exhaust gas exits the reaction chamber. The heating enclosure is configured to contain heated gas along the exterior of the reaction chamber, and the optional coolant channel is configured to contain a flow of coolant around the heating enclosure. The catalytic converter can further include a catalytic element in the reaction chamber.

I/We claim: 
     
         1 . A catalytic converter for treating a flow of exhaust gas, comprising:
 a reaction chamber having a catalytic element; and   a heating enclosure at least partially enclosing the reaction chamber, the heating enclosure providing a path for heated gas to flow in contact with an exterior of the reaction chamber.   
     
     
         2 . The catalytic converter of  claim 1  wherein the reaction chamber further includes a central bore, the central bore providing a path for the exhaust gas to enter the catalytic element. 
     
     
         3 . The catalytic converter of  claim 2  wherein the reaction chamber further includes a closed end and a plurality of ports, the plurality of ports providing a passageway for the heated gas to flow from the reaction chamber to the heating enclosure. 
     
     
         4 . The catalytic converter of  claim 1  wherein the reaction chamber includes a first end section where the exhaust gas flows into the reaction chamber and a second end section where the exhaust gas exits the reaction chamber. 
     
     
         5 . The catalytic converter of  claim 1  wherein the reaction chamber includes a plurality of ports, the plurality of ports providing a passageway for the exhaust gas to flow to and/or from the reaction chamber to the heating enclosure. 
     
     
         6 . The catalytic converter of  claim 5  wherein at least a first one of the plurality of ports is located upstream of the catalytic element, and wherein at least a second one of the plurality of ports is located downstream of the catalytic element. 
     
     
         7 . The catalytic converter of  claim 1  wherein the heating enclosure concentrically encloses at least a part of the reaction chamber. 
     
     
         8 . A catalytic converter for treating a flow of exhaust gas, comprising:
 a reaction chamber through which at least a portion of the exhaust gas flows, the reaction chamber having a catalytic element; and   a heating enclosure through which a heated flow passes, the heating enclosure enclosing at least a portion of the reaction chamber.   
     
     
         9 . The catalytic converter of  claim 8  wherein the heating enclosure comprises an annular plenum. 
     
     
         10 . The catalytic converter of  claim 8  wherein the at least a portion of the exhaust gas is a first portion of the exhaust gas, and wherein the heated flow comprises a second portion of the exhaust gas, the second portion of the exhaust gas separated from a primary flow of the exhaust gas upstream of the catalytic converter. 
     
     
         11 . The catalytic converter of  claim 10  wherein the reaction chamber includes a first end section where the first portion of the exhaust gas flows into the reaction chamber and a second end section where the first portion of the exhaust gas exits the reaction chamber, and wherein the second portion of the exhaust gas passes through the catalytic converter without passing through the reaction chamber. 
     
     
         12 . The catalytic converter of  claim 8  wherein the heated flow comprises raw air that has been heated by passing over heated portions of an engine or an exhaust system. 
     
     
         13 . The catalytic converter of  claim 8  wherein the heated flow comprises a sub-portion of the at least a portion of the exhaust gas, and wherein the reaction chamber includes a port, the port providing a passageway for the heated flow to pass from the reaction chamber to the heating enclosure. 
     
     
         14 . The catalytic converter of  claim 13  wherein the port further provides a passageway for the heated flow to pass from the heating enclosure to the reaction chamber. 
     
     
         15 . The catalytic converter of  claim 13  wherein the port is a first port, and wherein the reaction chamber further includes a second port, the second port providing a passageway for the heated flow to pass from the heating enclosure to the reaction chamber. 
     
     
         16 . A method for reducing emissions in exhaust gases, the method comprising:
 directing a flow of exhaust gases through a reaction chamber in a catalytic converter; and   heating an exterior portion of the reaction chamber by directing a flow of heated gas through a heating enclosure enclosing at least a portion of the reaction chamber.   
     
     
         17 . The method of  claim 16  wherein directing a flow of exhaust gases through a reaction chamber includes directing the flow of exhaust gases through a catalytic element. 
     
     
         18 . The method of  claim 16  wherein directing a flow of heated gas through a heating enclosure includes providing a port between the reaction chamber and the heating enclosure and directing a portion of the exhaust gas through the port. 
     
     
         19 . The method of  claim 16  wherein directing a flow of heated gas through a heating enclosure includes heating a flow of raw air by passing the raw air over heated portions of an engine or an exhaust system to produce the heated gas. 
     
     
         20 . The method of  claim 16  wherein directing the flow of exhaust gases through the reaction chamber includes directing the flow of raw air through a central bore in a catalytic element.