CN104870897A - Catalytic burner - Google Patents

Catalytic burner Download PDF

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Publication number
CN104870897A
CN104870897A CN201380064469.5A CN201380064469A CN104870897A CN 104870897 A CN104870897 A CN 104870897A CN 201380064469 A CN201380064469 A CN 201380064469A CN 104870897 A CN104870897 A CN 104870897A
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China
Prior art keywords
catalytic burner
porous
catalyst
component
media particle
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CN201380064469.5A
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CN104870897B (en
Inventor
阿伦·R·比贝尔
托马斯·E·伍德
亚当·C·申德尔
巴德理·维尔拉哈万
伊万·昆·伦·油吉·哈吉米
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3M Innovative Properties Co
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3M Innovative Properties Co
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23DBURNERS
    • F23D14/00Burners for combustion of a gas, e.g. of a gas stored under pressure as a liquid
    • F23D14/12Radiant burners
    • F23D14/18Radiant burners using catalysis for flameless combustion
    • F23D14/181Radiant burners using catalysis for flameless combustion with carbon containing radiating surface
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23CMETHODS OR APPARATUS FOR COMBUSTION USING FLUID FUEL OR SOLID FUEL SUSPENDED IN  A CARRIER GAS OR AIR 
    • F23C13/00Apparatus in which combustion takes place in the presence of catalytic material
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23DBURNERS
    • F23D2203/00Gaseous fuel burners
    • F23D2203/10Flame diffusing means
    • F23D2203/101Flame diffusing means characterised by surface shape
    • F23D2203/1012Flame diffusing means characterised by surface shape tubular
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23DBURNERS
    • F23D2212/00Burner material specifications
    • F23D2212/10Burner material specifications ceramic
    • F23D2212/105Particles

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Catalysts (AREA)
  • Gas Burners (AREA)

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.

Description

Catalytic burner
federal government subsidizes the statement of research
The present invention carries out under governmental support according to the contract number DE-EE0003491 authorized by Ministry of Energy.Government enjoys certain right in the present invention.
Technical field
The catalyst media that the disclosure relates to catalytic burner and wherein uses.
Background technology
In commercial boiler, the gaseous hydrocarbon fuel source of the heat exchanger inside held in boiler is converted into heat energy.Usually, the space of heat exchanger inside remains little, to make the minimized in size of boiler.In order to make operation and Environmental costs minimize, wish that fuel is effectively converted to heat energy and minimizes harmful side product (such as, NO x, CO) amount.
Previous trial solves this problem and relates to by porous distributor and diffuser plate that (this buzzword is more conventional, even if " plate " may be uneven) control the hydrodynamics of gas-air mixture, this porous distributor and diffuser plate are usually oriented as with one heart, coaxial clyinder and by heating resisting metal such as stainless steel structure.Although these design compacter and reduce NO xdischarge capacity, but this reducing amount is just becoming and cannot meet discharge standard strict gradually.
Summary of the invention
The disclosure overcomes the problems referred to above by setting up the catalyst media grain bed of the high-voidage mark filling be arranged between distributor and diffuser plate.Catalyst media particle reduces active combustion temperature, thus decreases generated hot NO xamount.The catalyst media grain bed of filling be realize fuel in the presence of a catalyst enough time of staying needed for.But the thickness (or degree of depth) of catalyst media grain bed and void fraction (ε) greatly affect the heat transfer rate of the fuel burnt in catalyst media grain bed.For too thick and/or that void fraction is too low catalyst media grain bed, heat from combustion reaction is removed from catalyst media grain bed poor efficiency, thus cause this temperature to raise rapidly and the stability limit temperature of catalyst may be exceeded, thus make its inactivation.
Under low void fraction, such as when spheric catalyst media particle (such as, void fraction is the monodisperse spherical particle of about 0.36) or crushed particles, according to the thickness of catalyst media grain bed, this bed tempertaure can more than 800 DEG C.
As used herein, term " void fraction " refers to volume and the master container volume (V of the void space in the container of filling full particle between particle container, with cubic centimetre (cm 3) represent) and ratio, and to be defined by following formula:
Wherein V outsidewith cubic centimetre (cm 3) external volume counted, comprise all solids material, open bore and impermeable part.External volume is defined as
V outside=W-S (2)
Wherein W be in gram saturated weight, S be in gram weight suspension, and test liquid is density is 1 gram/cc of (g/cm 3) water.Such as according to Xikang She Huoken ASTM International Standards Organization of Pennsylvania (ASTM International, West Conshohocken, Pennsylvania) to code " the Standard Test Methods for Apparent Porosity described in calcining refractory brick in the ASTM numbering C20-00 (ratifying again for 2010) formulated, WaterAbsorption, Apparent Specific Gravity, and Bulk Density of BurnedRefractory Brick and Shapes by Boiling Water " (measure the apparent porous of calcining refractory brick and special form brick with burning water, water imbibition, the standard method of test of apparent specific gravity and bulk density) calculate these.
High bed tempertaure can cause catalysqt deactivation and/or vapors away from surface and carry out this system with discharge stream.Although catalyst media particle can realize low NO xdischarge capacity, but high catalyst bed tempertaure reduces the validity of catalyst gradually.
Under larger void fraction, bed tempertaure increases with void fraction and reduces, and what accompany is catalyst media particle life, until under the void fraction being greater than 0.6, bed tempertaure is no more than 800 DEG C usually, and palladium catalyst shows longer life, still realizes low NO simultaneously xdischarge capacity.
In certain embodiments, catalyst media particle is substantially free of, or not even containing internal void space.
Therefore, in one aspect, the disclosure provides a kind of catalytic burner, and it comprises:
Porous air diffuser component;
Porous distributor component;
At least one seal, the seal extends between porous air diffuser component and porous distributor component, thus limits oxidizing chamber; With
Catalyst media particle, this catalyst media particle is used for the oxidation reaction of catalytic fuel stream to produce heat and to discharge stream, wherein this catalyst media particle is arranged in described oxidizing chamber, wherein this catalyst media particle comprises carrier granular, each carrier granular comprises refractory material, at least some wherein in this carrier granular has the external coating comprising oxidation catalyst thereon, and wherein the void fraction of this catalyst media particle is at least 0.6.
In certain embodiments, porous air diffuser component and porous distributor component comprise substantially parallel porous plate.In certain embodiments, porous air diffuser component comprises the first openend, and porous distributor component is at least partially disposed on porous air diffuser component inside, and porous distributor component comprises the second openend.
After consideration detailed description of the invention and appended claims, will be further understood that feature and advantage of the present disclosure.
Accompanying drawing explanation
Fig. 1 is the perspective illustration according to exemplary catalyst burner 100 of the present disclosure.
Figure 1A is the enlarged detail portions of the region 1A in Fig. 1.
Fig. 2 is the schematic cross sectional views of exemplary catalyst burner 200.
Fig. 3 is the amplification schematic cross sectional views of exemplary catalyst media particle 270.
Fig. 4 is the schematic cross sectional views of exemplary catalyst burner 400.
Fig. 5 is the microphoto of the exemplary saddle type carrier granular of preparation in " preparation of catalyst media particle E ".
Fig. 6 is according to the schematic cross sectional views comprising the exemplary boiler of catalytic burner of the present disclosure.
Reuse Reference numeral to be in the present description and drawings intended to represent same or analogous feature of the present disclosure or element.Should be appreciated that those skilled in the art can visualize fall into principle of the present disclosure scope and essence within multiple other amendment and embodiments.Accompanying drawing can not drawn on scale.
Detailed description of the invention
See Fig. 1, exemplary catalyst burner 100 has inlet opens 110, the adjacent seals 160 of fuel streams (not shown), this fuel streams is through the hole 113 (see Figure 1A) in porous distributor component 115, oxidized at burner internal, then discharge through the hole 129 in porous air diffuser component 120 as discharging stream (not shown).
The parts except catalyst media particle of catalytic burner can comprise any material of heat (such as, being up at least 800 DEG C) caused by the oxidation can bearing fuel streams and corrosion.Stainless steel (such as, grade 304 or 316) is this type of exemplary material.
Catalytic burner can have such as any suitable design as known in the art, comprises not in design exemplified here.The example of various design comprises cylindricality, and (such as, as Figure 1-3), conical butt is (such as, as PCT published application WO 2011/076220 A1 described), parallel-plate and spherical configuration (such as, as United States Patent (USP) 5,474,443 people such as () Viessmann are described).
Porous distributor component generally includes has multiple wall running through the hole of extension, can be formed as such as column tube, conical pipe, hollow spheres body or their combination, but this is not required.Hole can have any shape (such as, slit and/or circular hole) and pattern, but preferably size is fully set to that catalyst media particle does not extend there through.In certain embodiments, based on the total surface area meter of wall, the multiple holes in the wall of porous distributor component account for 1 to 30 area percentage, preferably 5 to 25 area percentages and more preferably 5 to 15 area percentages, but this is not required.Preferably, hole should be enough little, and this prevents tempering from lighting a fire.The selection of hole shape and size can be depending on composition and the pressure thereof of fuel streams, and will be known to persons of ordinary skill in the art.In certain embodiments, porous distributor component comprises the porous metal frit of sintering.
Equally, porous air diffuser component generally includes has multiple wall running through the hole of extension, can be formed as such as column tube, conical pipe, hollow spheres body or their combination, but this is not required.The same before this, hole can have any shape and pattern, but preferably size is fully set to that catalyst media particle does not extend there through.In certain embodiments, based on the total surface area meter of wall, the multiple holes in the wall of porous distributor component account for 10 to 90 area percentages, preferably 15 to 45 area percentages, but this is not required.In certain embodiments, porous air diffuser component comprises silk screen.
Usually, porous air diffuser component is suitable for encapsulating porous distributor component at least in part, be formed in the oxidizing chamber (such as, being filled with catalyst media particle at least in part) in the gap between porous air diffuser component and porous distributor component with substantial constant simultaneously.For for domestic boiler, gap is generally 0.5 millimeter to 3 millimeters, and higher gap usually has and is intended to and the commercial comparatively large-scale combustion device used together with Industrial Boiler.
In certain embodiments, porous distributor component and/or porous air diffuser component are hollow.
In an embodiment in fig. 2, the catalytic burner 200 with the same external general picture of catalytic burner 100 (shown in Fig. 1) comprises porous air diffuser component 220, this porous air diffuser component 220 comprises cylindrical conduit 221 and comprises the first openend 225 and the second openend 227, and cylindrical conduit 221 has the wall 222 with multiple hole (not shown) extended there through.Porous distributor component 230 (comprise the cylindrical conduit 231 with wall 232, wall 232 is with multiple hole 233 extended there through) is arranged on porous air diffuser component 220 inside and comprises the 3rd openend 235 and the 4th openend 237.First openend 225 is covered by the first end cap 240 and comprises alignment pin 245, and this alignment pin extends internally along the longitudinal axis 250 of porous air diffuser component 220.Second end cap 244 covers the 4th openend 237, but be suitable for receive alignment pin 245 central opening 239 except.Lip ring 260 extends between porous air diffuser component 220 and porous distributor component 230, thus limits (being combined with the first end cap 240) oxidizing chamber 270.
Catalyst media particle 280 is arranged in oxidizing chamber 270, and the oxidation reaction in catalytic fuel stream, thus produce heat and discharge stream.Catalyst media particle 280 comprises the carrier granular 284 containing refractory material.Catalyst media particle is filled with the void fraction of at least 0.6.
Optionally, tubulose screen cloth can be arranged on porous distributor component inside to prevent any fragment of the catalyst media particle that may be formed inwardly through the hole in porous air diffuser component.
Now referring now to Fig. 3, carrier granular 184 has the external coating 186 comprising oxidation catalyst 182.External coating 186 comprise the internal layer 188 comprising cerium oxide that contacts with carrier granular 184 and support package containing the skin 189 of oxidation catalyst.
In another embodiment shown in Fig. 4, the cylindricality catalytic burner 400 with the same external general picture of catalytic burner 100 (shown in Fig. 1) comprises porous air diffuser component 420, this porous air diffuser component comprises the cylindrical conduit 421 with wall 422 and comprises the first openend 425 and the second openend 427, and wall 422 is with multiple hole (not shown) extended there through.Cylindricality porous distributor component 430 (comprise the cylindrical conduit 431 with wall 432, wall 432 is with multiple hole 433 extended there through) is arranged on porous air diffuser component 420 inside and comprises the 3rd openend 435 and the 4th openend 437.First openend 425 is covered by end cap 440.3rd openend 435 engages the groove 446 in end cap 440, thus forms seal.Lip ring 460 extends between porous air diffuser component 420 and porous distributor component 430, thus limits (being combined with end cap 440) oxidizing chamber 470.Catalyst media particle 480 is arranged in oxidizing chamber 470.
In use, the oxidation reaction of catalyst media particulate catalytic fuel streams is to produce heat and to discharge stream.Catalyst media particle comprises multiple carrier granular, at least some of carrier granular its outer surfaces at least partially on there is external coating.Carrier granular is usual because of the technique (such as, by extruding or molding) for the preparation of them wittingly shaping (that is, not being that such as crushed particles or powder are such random shaping), but this is not required.The selection of the size of catalyst media particle is controlled by the size of burner and the spacing between porous distributor component and porous air diffuser component usually at least in part.In certain embodiments, the average grain diameter (that is, the full-size of particle) of catalyst media particle or maximum particle diameter are 0.5 to 20 millimeter, 0.5 to 6 millimeter, 0.5 to 3 millimeter, but also can use other particle diameters.Because external coating is usually thinner, the shape and size of catalyst media particle are usually substantially identical with carrier granular.
Average headway between diffuser element and distributor component is generally greater than the average grain diameter of catalyst media particle.In certain embodiments, the average headway between diffuser element and distributor component is 0.5 to 20 millimeter, 0.5 to 10 millimeter or 1 to 6 millimeter, but this is not required.
In certain embodiments, the shape of carrier granular is predetermined, such as, such as produced by molding process.Carrier granular comprises refractory material (that is, one or more refractory materials) and can be made up of refractory material.The example of suitable refractory material comprises aluminium oxide (such as, alpha-aluminium oxide, βAl2O3, gamma-alumina, η aluminium oxide and/or θ aluminium oxide), mullite, aluminium titanates, zirconia, zircon, silica, fire clay (lithomarge), cordierite, carborundum, and their mixture.The other example of suitable refractory material comprises the oxide being selected from following metal: magnesium, aluminium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, cerium, copper, zinc, gallium, germanium, strontium, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, silver, samarium, indium, iron, tin, antimony, barium, lanthanum, hafnium, tungsten, rhenium, iridium, platinum and their combination.Preferred refractory material comprises inorganic, metal oxide (such as, aluminium oxide and mullite).Preferably, refractory material has lower thermal coefficient of expansion and/or can tolerate multiple thermal cycle and not break and fragmentation.
Available carrier granular can available from commercial sources or such as prepare according to known method.Such as, alumina carrier particle is prepared by following steps: extrude and optionally shaping (such as, curling) comprise slurries or the sol-gel of alumina precursor (such as, the boehmite of colloidal state), extrudate is cut into Len req, dry extrudate particle, optionally calcine it, then sintered, these steps are substantially as United States Patent (USP) 4,314,827 (people such as Leitheiser); 4,518,397 (people such as Leitheiser); Described in 4,881,951 (people such as Monroe).Suitable saddle type carrier granular is shown in Figure 5 by following steps preparation: according in Examples below part described in " preparation of catalyst media particle E ", extrude boehmite sol-gel by the hollow needle with bent tip.
In certain embodiments, carrier granular has the cross-sectional profiles of substantial constant along its length.For the carrier granular formed by expressing technique, especially so.
Catalyst media particle with the mode therebetween with large quantity space fill (such as, they with at least 0.6 void fraction fill).In certain embodiments, void fraction is at least 0.63, at least 0.65, at least 0.68, at least 0.70, at least 0.72, at least 0.75, at least 0.78 or even at least 0.80.Preferably, catalyst media particle is not filled with orderly array.
Any shape or combination of shapes of filling with required void fraction can be used.The required void fraction example of shaped granule of filling can comprise curved rod, bend pipe and saddle type particle (such as, as in example hereafter).
Catalyst media particle can have any suitable solid density.Such as, they can have at least 1.5g/cm 3, at least 1.7g/cm 3, at least 1.9g/cm 3, at least 2.1g/cm 3, at least 2.3g/cm 3, at least 2.5g/cm 3, at least 2.7g/cm 3, at least 2.9g/cm 3, at least 3.0g/cm 3, at least 3.1g/cm 3, at least 3.3g/cm 3, at least 3.5g/cm 3, at least 3.6g/cm 3, at least 3.7g/cm 3, at least 3.8g/cm 3or even at least 3.9g/cm 3solid density.
At least some in carrier granular, preferably carrier granular at least great majority or even all its outer surface at least partially on there is external coating.By the technique that the degree that external coating covers will depend on for being deposited on the carrier particles usually.Such as, solvent coating process can effectively apply whole surface, and physical vapour deposition (PVD) can cause the part of independent carrier particle surface to cover.External coating can comprise one or more layer (such as, one, two or three layer).Skin can have any thickness, but usually thinner.Such as, it can have the thickness of 1 nanometer (nm) to 10 microns, preferably 1 nanometer to 1 micron.
External coating comprises the oxidation catalyst for the oxidisable gas in oxygenated fuel stream.This type of material is well known in the art and comprises and such as comprise platinum, iridium, osmium, palladium, ruthenium, rhodium, their alloy, their oxide and the material of their combination.Wherein, palladium and oxide thereof are preferred.
The known high catalytic activity had for methane oxidation of catalyst based on palladium.To it is believed that in these catalyst active the strongest be usually stable between 300 to 600 DEG C oxide form mutually.Higher than at the temperature of the rising of about 800 DEG C, except being made except active surface area reduces by such as sintering, palladium oxide (PdO) is also decomposed into Pd metal, it is believed that Pd metal active is not as good as oxide form.Importantly, metallic forms also has the volatility higher than oxide, therefore there is catalysis material during operation of combustors by more risk that evaporation process is lost.The optimum temperature range of these Considerations instruction between 300 to 600 DEG C make palladium catalyst according in catalytic burner of the present disclosure effectively and use chronically.
In certain embodiments, external coating comprises internal layer and skin, and these layers can comprise different materials.In one embodiment, internal layer (that is, the layer contacted with carrier granular) comprises cerium oxide.Internal layer support package is containing the skin of oxidation catalyst.Example dual layer structure and described by being prepared in Examples below in " preparation of catalyst media particle G " to have.
In some exemplary embodiments, use physical vapour deposition (PVD) by catalytic activity palladium deposition on the carrier particles.Physical vapour deposition (PVD) refers to that palladium is from the physical transfer containing palladium source or targeting vector particle.Physical vapour deposition (PVD) can be regarded as relating to an atom and connect one and deposit atomically, but in the implementation process of reality, palladium also can shift as ultrafine granule, and each granule is by more than one atomic building.Once be in the surface of carrier granular, can there is the interaction of physics, chemistry, ion and/or other modes with surface in palladium.
There is the multiple different method for implementing physical vapour deposition (PVD) (PVD).Representational method comprises sputtering sedimentation, evaporation and cathodic arc deposition.Can use any one in these methods or other PVD methods, but the character of the PVD technology adopted can affect catalytic activity.Such as, the energy of the physical gas phase deposition technology of use can affect mobility, and the palladium atom therefore deposited and bunch be tending towards being agglomerated into larger granule on carrier surface.Higher energy is tending towards corresponding to the coalescent trend of palladium increased.Coalescent being then tending towards increased reduces catalytic activity.In general, the minimum energy of deposited material in evaporation, higher in sputtering sedimentation (wherein can comprise some ion concentrations, the metallics generation ionization of its small portion collision), the highest (ion concentration wherein can account for tens percent) in cathode arc.Therefore, if a kind of concrete PVD technology causes the palladium deposited than required easier movement, then it may be useful for substituting by more low-energy PVD technology.
In general, physical vapour deposition (PVD) is the aiming formula/surface coating technique between palladium source and carrier granular.This means the exposed outer surface of only directly coated carrier particle, and do not apply endoporus (if any) completely in the substrate.Although the inner surface that non-immediate aims at source also will be tending towards directly not being coated with palladium, in some matrix, the atom of the palladium of deposition and tuftlet can be permeated by being diffused into small distance in porous carrier particle.
In some preferred embodiments, active palladium material is substantially complete to be collected in the outermost part of carrier granular.This is desirable, because such as in buner system, this is easy to the surface with the interactional catalyst system of oxidable gas most.
Palladium metal can be the form of metal, oxide or some other oxidised forms, and can have the oxidation state of such as 0 ,+2 or+4.In general, preferably, palladium exists with oxidised form at least partially during catalytic burner is just promoting burning.
In certain embodiments, physical vapour deposition (PVD) palladium metal on the carrier particles can have the thickness of 0.1nm to 500nm, 1nm to 400nm or even 5nm to 250nm.
For using in the boiler, catalytic burner is usually connected to inlet component and is arranged in boiler, and this inlet component has ingress port, and this ingress port is communicated with inlet opens fluid supplies fuel streams for from source.
Referring now to Fig. 6, exemplary boiler 600 comprises catalytic burner 605, and this catalytic burner is connected to inlet component 610 and is arranged in the cavity 615 in shell 630.Inlet component 610 comprises ingress port 620, and this ingress port is communicated with inlet opens 625 fluid of catalytic burner 605 supplies fuel streams 670 for from source.Shell 630 has discharge port 640 and heat exchanger coils 650 for cycling hot replacement fluids (such as, water).Once oxidation, then fuel streams is converted into and discharges stream 690, and this discharge stream discharges from catalytic burner 600, walks around insulation barrier 680, through heat exchanger coil 650, then discharges through discharge port 640.
Boiler also can comprise one or more other parts, such as such as condensate drain.
Typical fuel streams is gaseous state, and usually comprises oxidizable components and oxidizing component (that is, oxidant).The example of suitable oxidizable components comprises acetylene, methane, ethane, propane, butane, pentane and their combination, but also can use other oxidable gaseous materials.The example of suitable oxidizing component comprises air, oxygen (pure or be combined with other gases such as nitrogen, carbon dioxide and/or rare gas, such as in atmosphere) or another kind of oxidizing gas (such as, nitrous oxide).
Such as family expenses, commercialization and/or Industrial Boiler is can be used for according to catalytic burner of the present disclosure.
As used herein, word form " comprises ", " having " and " comprising " is equal to legally and has open implication.Therefore, except enumerate element, function, step or restriction except, also can there is other elements do not enumerated, function, step or restriction.
selected embodiment of the present disclosure
In a first embodiment, the disclosure provides a kind of catalytic burner, and it comprises:
Porous air diffuser component;
Porous distributor component;
At least one seal, the seal extends between porous air diffuser component and porous distributor component, thus limits oxidizing chamber; With
Catalyst media particle, this catalyst media particle is used for the oxidation reaction of catalytic fuel stream to produce heat and to discharge stream, wherein said catalyst media particle is arranged in oxidizing chamber, wherein said catalyst media particle comprises carrier granular, each carrier granular comprises refractory material, at least some in wherein said carrier granular has the external coating comprising oxidation catalyst thereon, and the void fraction of wherein said catalyst media particle is at least 0.6.
In a second embodiment, the disclosure provides the catalytic burner according to the first embodiment, wherein said porous air diffuser component comprises the first openend, wherein said porous distributor component is at least partially disposed on described porous air diffuser component inside, and wherein said porous distributor component comprises the second openend.
In the third embodiment, the disclosure provides the catalytic burner according to the first or second embodiment, described catalytic burner also comprises the first end cap, and wherein said porous air diffuser component also comprises the 3rd openend, and wherein said first end cap covers described first openend.
In the fourth embodiment, the disclosure provides the catalytic burner according to the 3rd embodiment, and described catalytic burner also comprises the second end cap, wherein:
Described first end cap comprises the alignment pin that the longitudinal axis along described porous distributor component extends internally from it;
Described porous distributor component also comprises the 4th openend; And
Described second end cap covers described 4th openend, but is suitable for receiving except the central opening in described second end cap of described alignment pin.
In the 5th embodiment, the disclosure provides the catalytic burner according to the 3rd or the 4th embodiment, and wherein said porous air diffuser component comprises at least one in cylindrical conduit or frustum of a cone conduit.
In the sixth embodiment, the disclosure provides the catalytic burner according to any one of the first to the 5th embodiment, and wherein said porous air diffuser component comprises head.
In the 7th embodiment, the disclosure provides the catalytic burner according to any one of the first to the 6th embodiment, and wherein said external coating is discontinuous.
In the 8th embodiment, the disclosure provides the catalytic burner according to any one of the first to the 7th embodiment, and wherein said void fraction is at least 0.65.
In the 9th embodiment, the disclosure provides the catalytic burner according to any one of the first to the 8th embodiment, the average distance of wherein said porous distributor component and described 1 to 6 millimeter separated from one another of porous air diffuser component.
In the tenth embodiment, the disclosure provides the catalytic burner according to any one of the first to the 9th embodiment, and the average grain diameter of wherein said catalyst media particle is 0.5 millimeter to 3 millimeters.
In the 11 embodiment, the disclosure provides the catalytic burner according to any one of the first to the tenth embodiment, and wherein said carrier granular is saddle type.
In the 12 embodiment, the disclosure provides the catalytic burner according to any one of the first to the 11 embodiment, and wherein said carrier granular has the cross-sectional profiles of substantial constant along its length.
In the 13 embodiment, the disclosure provides the catalytic burner according to the 12 embodiment, and wherein said oxidation catalyst comprises palladium.
In the 14 embodiment, the disclosure provides the catalytic burner according to the 13 embodiment, and wherein said palladium is deposited by physical vapour deposition (PVD).
In the 15 embodiment, the disclosure provides the catalytic burner according to any one of the first to the 14 embodiment, wherein said external coating comprises the internal layer containing cerium oxide, and described internal layer contacts also support package and contains the skin of described oxidation catalyst with described carrier granular.
In the 16 embodiment, the disclosure provides the catalytic burner according to any one of the second embodiment, described catalytic burner also comprises gas access component, described gas access component covers described first openend of described porous distributor component, and wherein said gas access component comprises gas inlet port.
In the 18 embodiment, the disclosure also comprises the screen cloth being at least partially disposed on described porous distributor component inside.
In the 19 embodiment, the disclosure provides a kind of boiler, and described boiler comprises:
According to catalytic burner of the present disclosure, described catalytic burner is arranged in the cavity in shell, and wherein said catalytic burner is connected to inlet component, and described inlet component comprises ingress port for supply fuel streams;
For the heat exchanger of cycling hot replacement fluids, described heat exchanger is arranged in described shell, and be communicated with described catalytic burner fluid, wherein said shell also comprises discharge port, described discharge port is communicated with described ingress port fluid by described catalytic burner.
Further illustrate object of the present disclosure and advantage by following limiting examples, but the concrete material described in these examples and consumption thereof, and other condition and details should not be considered as carrying out improper restriction to the disclosure.
example
Unless otherwise stated, all numbers, percentage, ratio etc. in the remainder of example and this description are by weight.
palladium content assay method
Use Inductively coupled plasma optical mission spectrometry method (ICP-OES) equipment (with Perkinelmer Inc. (PerkinElmer of trade name OPTIMA 4300DV purchased from Waltham, Massachusetts, Waltham, Massachusetts)) measure the palladium content of catalyst media particle.The external calibration curve of the acid comparison solution standard generation of 0,0.5,1 and 2 PPM (ppm) palladiums is comprised, analysis of catalyst media particle for use.The accuracy of calibration curve during using the quality control standard thing of 0.5ppm to carry out monitoring analysis.The scandium solution of 0.5ppm and catalyst media particle with flow online together with interior target standard items.
Catalyst media particle is measured with repeat samples.Each repeat samples of about 100mg is weighed in corresponding acid-washed quartz beaker.The concentrated sulfuric acid of about 2mL is added to sample beaker to neutralize in two empty map beakers.Beaker covers the quartz surfaces ware of pickling, and heats two hours under backflow (about 337 DEG C).Then, partial breakaway beaker evaporates, until obtain the liquor capacity of about 0.5mL to allow excessive acid.In each beaker, add 30% hydrogen peroxide of about 1mL, add the chloroazotic acid (3:1HCl:HNO of 4mL subsequently 3), and solution is heated to about 90-100 DEG C continue 15 minutes.Then the deionized water of about 10mL is added, and gradually heated solution, until remaining solid is partly dissolved.Cooling repeat samples and tester, quantitatively transfer in polypropylene centrifuge tube, be diluted to 25mL by deionized water, and be placed in ICP-OES equipment.Palladium content is with the palladium percentage by weight record based on catalyst media particle total weight.
the preparation of catalyst media particle
the preparation of catalyst media particle A
At 1200 DEG C, initial heat treatment 8 hours (hereinafter referred to as carrier granular A) is carried out to the gamma-alumina spheroid (the Sa Suoer company (Sasol LLC, Houston, Texas) of Houston, Texas) of 1.8mm.The void fraction of carrier granular A is 0.38, as use formula 1 and 2 and ASTM C20-00 (all describing above) calculate.Then evaporated by the controlled solvent of metal oxide sol and metal salt solution, will based on being found in the people such as Haneda, Bull.Chem.Soc.Jpn. (1993), vol.66, pp.1279-1288 (people such as Haneda, " Japanization association circular ", 1993 years, 66th volume, 1279-1288 page) the nanoporous support deposition of material that is made up of the oxide (5.25 % by weight) of cerium and aluminium of amendment synthetic method on the surface of carrier granular A.In brief, carrier granular A (soaking close to initial humidity) is soaked with the acidic aqueous sol comprising boehmite and cerous nitrate, and remove solvent, thus generating portion is dry, the spheroid of coating, at 600 DEG C, then calcine 4 hours to form metal oxide (hereinafter referred to as " Ce/Al oxide ") coating.Based on weight pick-up, the typical weight percentage of Ce/Al oxide is about 5 % by weight of the carrier granular of gained coating.
Then magnetron sputtering and particle agitator system is used, to various load level on the carrier granular by physical vapour deposition (PVD) (PVD) palladium being deposited on Ce/Al oxide-coated.Each sample of the carrier granular of Ce/Al oxide-coated is placed in the PVD equipment described in [0074]-[0076] section of Fig. 1 and 2, especially U.S. Patent Application Publication 2009/054230 A1 (people such as Veeraraghavan), unlike, blade 42 does not comprise hole 44.Particle agitator 16 has the impeller clearance of 6.3mm.Then vacuum chamber 14 is evacuated to about 5 × 10 -5holder (6.6mPa) or lower background pressure, make argon sputter gas and enter this room with the pressure of about 10 millitorrs (133.3mPa).The mass flow controller with reader (can purchased from MKS Instruments Inc. of Wilmington, Massachusetts (MKS Instruments, Inc., Wilmington, Massachusetts)) be used for the flow velocity of argon gas in control room, and argon gas flow velocity remains on 47 sccm (sccm).Then by carrying out palladium depositing operation to the period that presets that palladium sputtering target 32 is powered 2 hours, wherein particle stirrer shaft 40 and blade 42 rotate with 6rpm.The duration of palladium depositing operation is 2 hours.The palladium sputtering target power applied is 110 watts.
After completing palladium depositing operation, pass into air in a vacuum chamber and reach environmental condition, and the coated particle (catalyst media particle A) of gained is removed from PVD equipment.Recording palladium content according to palladium content assay method (above) is 0.19 % by weight Pd.
the preparation of catalyst media particle B
Catalyst media particle B is the mixture of the catalyst media particle A of the carrier granular A and 50% of 50% (by volume).
the preparation of catalyst media particle C
Palladium is deposited on carrier granular A by the preparation method according to catalyst media particle A, thus obtains catalyst media particle C.Catalyst media particle C does not comprise Ce/Al oxide coating.Recording palladium content according to palladium content assay method (above) is 0.18 % by weight Pd.
the preparation of catalyst media particle D
The prepared product of catalyst media particle D is the mixture of the catalyst media particle C of the carrier granular A and 50% of 50% (by volume).
the preparation of catalyst media particle E
Utilize the following solid boehmite gel of 40 % by weight, use pin expressing technique to form saddle type carrier granular.By carrying out high shear mixing 13 minutes in the solution of water-based nitric acid (212 parts) comprising water (7087 parts) and 70%, carry out dispersible boehmite alumina powder (4824 parts, with " DISPERAL " the Sha Suo North America Co., Ltd (SasolNorth America Inc.Houston Texas) purchased from Houston, Texas).Before use by aging for gained sol-gel at least 1 hour.
Aging sol-gel is made to be extruded through No. 10 pins, these No. 10 pins axis crimping and end is cut into about 45 ° to cause the curling of extruded parts along the longitudinal.Once extrude, then by the cut-out of saddle type sol-gel particle, dry also roasting.Roasting distribution map (firing profile) is 20 DEG C/min of 750 DEG C, 18 minutes heat refinings of edging up, 20 DEG C/min of edge up 1200 DEG C, 48 minutes heat refinings and 20 DEG C/min are cooled to 25 DEG C.
Fig. 5 is the representative optical microscope image of the saddle type alpha-aluminium oxide carrier granular through roasting.Saddle type alpha-aluminium oxide carrier granular through roasting has the average longest dimension of about 2 millimeters.The void fraction of these particles is 0.61, as use formula 1 and 2 and ASTM C20-00 (all describing above) calculate.This medium is hereinafter referred to as carrier granular B.Palladium is deposited on carrier granular B by the preparation method according to catalyst media particle A, causes Pd content to be 0.21 % by weight, thus obtains catalyst media particle E.Catalyst media particle E does not comprise Ce/Al oxide coating.
the preparation of catalyst media particle F
Catalyst media particle F is the mixture of the catalyst media particle E of the carrier granular B and 50% of 50% (by volume).
the preparation of catalyst media particle G
To with trade name BEKAERT BEKINIT 100 purchased from the thickness of NV Bekaert SA (Bekaert, Kortrijk, Belgium) of Belgium Courtrai for about 1.5mm and surface density are for 1,500g/m 2feCrAl metallic fiber mesh sheet heat-treat to 900 DEG C and continue 4 hours, thus obtain carrier mesh sheet A.Use the method similar with the method described in catalyst media particle A to apply Ce/Al oxide, thus obtain the Ce/Al oxide content of 3.56 % by weight.Then use physical vapour deposition (PVD) to continue 5 minutes with Pd gas phase coated carrier mesh sheet A under 250 watts, thus obtain the Pd content (relative to total matrix quality) of 0.06 % by weight.PVD equipment describes in fig 1 and 2, and especially describe in [0074]-[0076] section of U.S. Patent Application Publication 2009/054230 A1 (people such as Veeraraghavan), be arranged in the planar supports (replacing 16) parallel with Pd target unlike matrix.
performance test
pressure fall-off test
Be 17mm and bed thickness is the pressure drop of measuring the bed crossing over carrier granular A and B in the pipe of the vertical filling of 3 to 20mm at internal diameter.By mesh sheet screen cloth (the 150-160 micron opening stainless steel mesh sheet on either side), the bed of particle or mesh sheet is remained on appropriate location; the air wherein measured enters in the bottom of bed; be advanced through grain bed, be then discharged in atmospheric environment at top.By measuring just at the pressure of medium upstream and the atmospheric pressure in downstream, calculate pressure reduction.Use identical device measuring to cross over the pressure drop of carrier mesh sheet A, wherein fiber mat substituted for packed bed and has the diameter of the internal diameter equaling testing equipment.Table 1 and 2 (below) have recorded the result of carrier granular A and B and carrier mesh sheet A.
table 1
table 2
example 1
At boiler (the NTI Trinity Ti150 of house-hold size, can from NY Thermal company (the NY Thermal-St.John of California New Brunswick province St. John's, NewBrunswick, California) commercially available) in carry out boiler test.The commercially available acquisition of burner, and there is FeCrAl metallic fiber mesh sheet.This mesh sheet is removed and replaces with the various medium for testing.(544-5440MJ/h/m is equal to the roasting speed of 30% excess air (EA) and 15.8-158MJ/h (15-150kBtu/h) 2(48-480kBtu/h/ft 2) input power density) carry out experiment.Boiler inlet water temperature is constant remains on 60 DEG C, and is 11 DEG C through the temperature rise (outlet temperature deducts inlet temperature) of boiler.To gaseous effluent sampling from the smoke evacuation of boiler, and before being sent to a series of gas analyzer, gaseous effluent is made to pass cooler to remove any steam.Horiba VIA-510 gas analyzer (California that gulf (Irvine, California)) is used to be measured the concentration of carbon dioxide, carbon monoxide and methane in sampled gas by infrared absorption method.Use the Teledyne T200m NO of the advanced pollution detection instrument company (Teladyne Advanced Pollution Instrumentation, SanDiego, California) of the Te Lidan deriving from San Diego, CA xanalyzer measures nitrogen oxide (NO by chemoluminescence method x) concentration.Emissions data is diluted 0% oxygen be corrected in sample gas.Table 3 have recorded the NO from these tests xemission result.
First two groups of data compare carrier mesh sheet A and catalyst media particle G.In whole roasting scope, catalyst media particle G does not show the remarkable deviation with carrier mesh sheet A.This is because the aiming of physical vapour deposition (PVD) limits, thus produces the only limited face coat penetrating mesh sheet thickness.To provide between fuel with catalyst insufficient contacts in covering in this set of surfaces, and limit its validity.The two groups of data of next are for catalyst media particle B and catalyst media particle A.Relative to carrier mesh sheet A and catalyst media particle G, the medium of filling all illustrates NO under low roasting speed and high roasting speed xthe remarkable reduction of discharge capacity.
table 3
example 2
Burner test is carried out in the open burning device of customization.Service property (quality) flow controller (controls the Alborg company (Aalborg in fort purchased from Oran, New York with AALBORG GFCS-010066, Orangeburg, New York)) measure methane and dry air, and sent the mixing chamber by comprising a series of apertured disk.Then burn the gas of premixed in semi-cylinder burner head, the geometry of the boiler-burner in this semi-cylinder burner head simulative example 1 and being arranged on tabular surface.Use the temperature of K type thermocouple (health is the Omega engineering company (Omega Engineering, Stamford, Connecticut) of Stamford, Dick state) monitoring packed bed, the method described in use-case 1 measures discharge capacity simultaneously.Owing to being mingled with environmental gas in gas sampling, use the carbon dioxide and unburned methane concentration that record by NO xresultant scaled is to for the suitable combustion product of known input.Table 4,5 summarizes the NO of carrier B, carrier A, catalyst media particle D and catalyst media particle F xdischarge capacity and packed bed temperature data.First catalyst is compared to NO xthe effect of discharge capacity, when medium is catalyzed, the discharge capacity of carrier B and carrier A all significantly reduces.But the NO of catalyst media particle F xdischarge capacity illustrates the minimal improvement compared to catalyst media particle D, although there is the pressure drop difference shown in table 1,2.But medium temperature data have significant difference.For catalyst media particle F, not only packed bed temperature all keeps below 600 DEG C under all roasting conditions, and keeps stable 322-575 DEG C within the scope of whole roasting, but not drops to lower than 200 DEG C (as shown in catalyst media particle D).In addition, there are not 1200 DEG C of temperature peaks in catalyst media particle F under low firing condition, as during initial cycle, the spheroid of catalysis is visible.This causes wider working range, and within the scope of this, the existing activity of catalyst is again heat-staple.This has great significance for catalyst life.
table 4
table 5
When not departing from essence of the present disclosure and scope, those of ordinary skill in the art can put into practice other amendment and modification of the present disclosure, and essence of the present disclosure and scope have in the dependent claims and more specifically illustrate.Should be appreciated that the aspect of various embodiment can integrally or partly exchange with other aspects of various embodiment or combine.The full text of the bibliography of all references in the patent application of patented certificate above, patent or patent application is incorporated herein by reference by consistent mode.When there is inconsistent or contradiction between the bibliography part be incorporated to and present patent application, should state in the past bright in information be as the criterion.Put into practice the claimed disclosure to enable those of ordinary skill in the art and given aforementioned explanation should not be understood as restriction to the scope of the present disclosure, the scope of the present disclosure limited by claims and all equivalents thereof.

Claims (14)

1. a catalytic burner, comprising:
Porous air diffuser component;
Porous distributor component;
At least one seal, described seal extends between described porous air diffuser component and described porous distributor component, thus limits oxidizing chamber; With
Catalyst media particle, described catalyst media particle is used for the oxidation reaction of catalytic fuel stream to produce heat and to discharge stream, wherein said catalyst media particle is arranged in described oxidizing chamber, wherein said catalyst media particle comprises carrier granular, each carrier granular comprises refractory material, at least some in wherein said carrier granular has the external coating comprising oxidation catalyst thereon, and the void fraction of wherein said catalyst media particle is at least 0.6.
2. catalytic burner according to claim 1, wherein said porous air diffuser component comprises the first openend, wherein said porous distributor component is at least partially disposed on described porous air diffuser component inside, and wherein said porous distributor component comprises the second openend.
3. catalytic burner according to claim 1 and 2, described catalytic burner also comprises the first end cap, and wherein said porous air diffuser component also comprises the 3rd openend, and wherein said first end cap covers described first openend.
4. catalytic burner according to claim 3, described catalytic burner also comprises the second end cap, wherein:
Described first end cap comprises the alignment pin that the longitudinal axis along described porous distributor component extends internally from it;
Described porous distributor component also comprises the 4th openend; And
Described second end cap covers described 4th openend, but is suitable for receiving except the central opening in described second end cap of described alignment pin.
5. the catalytic burner according to claim 3 or 4, wherein said porous air diffuser component comprises at least one in cylindrical conduit or conical butt conduit.
6. catalytic burner according to any one of claim 1 to 5, wherein said external coating is discontinuous.
7. catalytic burner according to any one of claim 1 to 6, wherein said void fraction is at least 0.65.
8. catalytic burner according to any one of claim 1 to 7, the average distance of wherein said porous distributor component and described 1 to 6 millimeter separated from one another of porous air diffuser component.
9. catalytic burner according to any one of claim 1 to 7, the average grain diameter of wherein said catalyst media particle is 0.5 millimeter to 3 millimeters.
10. catalytic burner according to any one of claim 1 to 9, wherein said carrier granular is saddle type.
11. catalytic burners according to any one of claim 1 to 10, wherein said carrier granular has the cross-sectional profiles of substantial constant along its length.
12. catalytic burners according to any one of claim 1 to 11, wherein said oxidation catalyst comprises palladium.
13. catalytic burners according to claim 12, wherein said palladium is deposited by physical vapour deposition (PVD).
14. catalytic burners according to any one of claim 1 to 13, wherein said external coating comprises the internal layer containing cerium oxide, described internal layer contact with described carrier granular and support package containing the skin of described oxidation catalyst.
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