Abstract: An embodiment of a method for producing a gas treatment device includes disposing a mat support material about a substrate to form a subassembly; passing at least a portion of the subassembly into a main body portion of a housing that has a first portion having a decreasing internal diameter from a first end to the main body portion, the main body portion extending from the first portion.

Abstract: The catalytic exhaust gas cleaning system and a corresponding compensation layer are especially suitable for automotive applications. The novel configuration reliably protects a so-called swelling mat from strongly pulsating streams of exhaust gases, even at very high ambient temperatures. A compensation layer which includes the swelling mat and an insulting mat is disposed between an outer housing and a honeycomb of an exhaust gas purification system. An edging is produced preferably by folding the insulating mat. The folder-over edge bead is thicker than the remaining inner area of the insulating mat. Next to the side of the inner area facing away from the honeycomb, the welling mat is arranged so that the thicker area of the edging of the insulating mat covers those edge areas of the swelling mat which are at risk of abrasion. The compensation layer preferably consists of a composite material which can be wound.

Abstract: The present invention provides a support structure for a catalyst disposed within an outer containment. Several unique arrangements and connections of supporting struts that form the structure provide a number of significant advantages and improvements. The support structure provides a very low disturbance of gas flow while maintaining a high amount of contact support with catalyst foils. In addition to a high tolerance of thermal gradients and fewer stress concentrations, strong support in radial and axial directions is also provided.

Abstract: A canning structure comprises a ceramic honeycomb structure before carrying a catalyst, fixed beforehand within a metal case by a holding material. An impermeable layer is provided on at least one edge plane in the longitudinal direction of the holding material. Thus, the holding material does not carry expensive catalyst at the time of carrying catalyst, and accordingly chipping and cracking of the ceramic honeycomb structure can be prevented at the time of transporting, the catalyst carrying process, the canning process, and handling in each of the processes.

Abstract: A device (10) for treatment of exhaust gases includes a housing (12); a fragile structure (18) resiliently mounted within the housing (12); and a non-intumescent mounting mat (20) disposed in a gap between the housing (12) and the fragile structure (18). The mounting mat (20) comprises melt-formed, leached glass fibers high in silica content and exerts a minimum holding pressure for holding the fragile structure (18) within the housing (12) of one of (i) at least 10 kPa after 1000 cycles of testing at a hot face temperature of 900° C., a gap bulk density of between 0.3 and 0.5 g/cm3, and a percent gap expansion of 5 percent, and (ii) at least 50 kPa after 1000 cycles of testing at a hot face temperature of 300° C., a gap bulk density of between 0.3 and 0.5 g/cm3, and a percent gap expansion of 2 percent.

Abstract: An apparatus provides for increased feed throughput without loss of conversion or selectivity by increasing the catalyst volume in a final reactor of at least three reaction zones. The catalyst volume of the final reactor may be larger because the inner and outer screens that define a radial flow bed are extended. A low LHSV is maintained by increasing the catalyst volume in the final reactor.

Abstract: A special bearing mat (4) is used for mounting and insulating ceramic monoliths (1, 2) in a preferably oval housing (3) of an automobile exhaust system (20), especially for non-round housing cross sections. The bearing mat (4) and/or said housing is/are specially structured and/or chemically treated, especially impregnated at the points which are at risk of eroding (A) in order to increase resistance to erosion. The bearing mat (4) is adapted to suit the functioning of the exhaust system (20) during operation and is especially configured with several layers.

Abstract: A manufacturing process for producing a particulate reactor substrate according to the invention includes the steps of first roll-stamping small, raised dimples into the fabric substrate to control its coiled density. The dimpled fabric then undergoes high temperature firing for hardening and degreasing, and then water quenching to harden the metal which improves heat tolerance. The treated metal weave is then aluminum oxide shot-blasted to etch the fabric surface for improved ceramic coating adhesion and to increase surface area. Next, the fabric is coated with a wet slurry of an undercoating (“wash coat”) prior to spooling and pressing the fabric into individualized cartridges that are held tightly wound by an encircling sleeve. Next, the sleeved spools are oven-fired and then the fired spools are impregnated with the catalytic precious metal. The impregnated sheathed spools are finally oven-fired again and “canned” into an outer enclosure.

Abstract: A non-intumescent mat for providing a support structure for low temperature fragile structures in exhaust gas treatment devices, such as catalytic converters, diesel particulate traps, and like, comprising amorphous inorganic fibers. The fibers have Young's Modulus of less than about 20×106 psi and a geometric mean diameter less than about 5 ?m. The mat is adapted to provide a holding force of at least 15 psi throughout an average mat temperature range from ambient temperature up to at least about 350° C. The amorphous inorganic fibers are preferably melt formed fibers comprising the fiberization product of a melt comprising alumina/silica.

Abstract: An autothermal reactor and method for producing synthesis gas in which a heated oxygen containing stream is expanded into a mixing chamber to entrain a hydrocarbon containing stream to form a reactant stream without reaction of the oxygen and hydrocarbon contents of the streams. The reactant stream is reacted in a series of sequential catalytic reaction zones to react the hydrocarbon and oxygen contained in the reactant stream to form the synthesis gas. The sequential catalytic reaction zones are configured such that an initial partial oxidation reaction occurs that is followed by endothermic reforming reactions having ever decreasing temperatures. The sequential catalytic reaction zones in which the endothermic reforming reactions occur contain a precious metal catalyst supported on ceramic supports that have successively greater surface areas to compensate for the temperature decrease while remaining stable and without a transform in state.

Abstract: A fixed bed containing a particulate catalyst or sorbent material (10) subject to operation at high temperature having a shaped boundary member (16) inclined to the direction of fluid flow through the bed that maintains the depth of said catalyst or sorbent at the boundary of the bed through a series of thermal expansion-thermal contraction cycles is described. By maintaining bed depth, the shaped boundary member (16) can prevent bypass of, e.g. ammonia through a bed of particulate ammonia oxidation catalyst.

Abstract: A safe, reliable chemical reactor (1, 20) with a simple construction, easy to assemble and to disassemble comprises a casing (2), a male member (3) supported by the casing (2) and inserted with a certain clearance in a female member (4) associated to the casing (2), as well as a metallic foil (10) capable of being deformed fixedly connected to the male member (3) and protruding into said clearance (8), in order to hinder the fluid passage through the clearance.

Abstract: An insulating liner for use with exhaust system or pollution control devices such as catalytic converters and diesel particulate filters or traps. The insulating liner is shown in relation to an end cone for use with a catalytic converter. The end cone includes an outer metallic end cone and a free-standing insulating cone positioned within the outer metallic end cone. A substantial portion of the inner surface of the insulating liner is exposed to hot exhaust gas from an internal combustion engine. The insulating liner is preferably formed of a composite containing inorganic fibers and/or particles, which makes the insulating liner rigid, yet capable of withstanding repeated mechanical and thermal shocks.

Abstract: A conical reactor head for use in chemical processes or other systems is provided. The reactor head includes a robust internal insulator to boost efficiency while maintaining safety by allowing the reactor head to self-radiate at high temperatures. The reactor head also includes a plurality of support lugs to protect its bottom flange from scratches or other damage when the reactor head is set on the ground. The reactor head is adapted to connect to a catalyst-containing barrel which is specially designed to facilitate easy installation and removal of catalysts or other equipment from outside the barrel. The reactor may be coupled with a rotation vane to induce laminar flow at the inlet of the reactor to increase reactor efficiency and prolong catalyst life.

Abstract: An outlet system in a reforming catalytic reaction apparatus for cracking hydrocarbons for the production of hydrogen (H2) includes differently dimensioned inlet and outlet reaction tubes attached to and in flow communication with one another; and an external layer of thermal insulation material surrounding a part of the outlet reaction tube

Abstract: Disclosed is a method and apparatus for reducing the amount of metal catalyzed side-reaction byproducts formed in the feed vaporization and introduction system of a methanol to olefin reactor system by monitoring and/or maintaining the temperature of at least a portion of the feed vaporization and introduction system and/or of the feedstock contained therein below about 400° C., 350° C., 300° C., 250° C., 200° C. or below about 150° C. The temperature can be maintained in the desired range by jacketing at least a portion of the feed vaporization and introduction system, such as at least a portion of the feed introduction nozzle, with a thermally insulating material or by implementing a cooling system.

Abstract: A conical reactor head for use in chemical processes or other systems is provided. The reactor head includes a robust internal insulator to boost efficiency while maintaining safety by allowing the reactor head to self-radiate at high temperatures. The reactor head also includes a plurality of support lugs to protect its bottom flange from scratches or other damage when the reactor head is set on the ground. The reactor head is adapted to connect to a catalyst-containing barrel which is specially designed to facilitate easy installation and removal of catalysts or other equipment from outside the barrel.

Abstract: The device for removing pollution from the exhaust gases of an internal combustion engine includes an exhaust box (12) containing, in series, a catalytic purification unit (18) and a particle filter (20). The exhaust box (12) includes means (36; 60) providing access to the upstream face of the particle filter (20). Application to removing pollution from automobile vehicle diesel engines in particular.

Abstract: A pollution control device has a metal housing, a solid pollution control device disposed within the metal housing, and a mounting mat disposed between the pollution control element and the housing for positioning the pollution control element and for absorbing mechanical and thermal shock. The mounting mat includes a layer of intumescent material having at least one insert formed of a resilient, flexible, fibrous non-intumescent material. The insert is positioned along at least a portion of at least one lateral edge of the mounting mat to prevent erosion of the intumescent material and to provide a seal between the pollution control element and the housing.

Abstract: The invention concerns a module for the synthesis of organic molecules on or in solid phase and an apparatus comprising at least such a module.

Abstract: The invention relates to an apparatus for the conversion of hydrocarbons to hydrogen, and to the conversion process. Fuel processors, or reformers are often used for large-scale conversion of natural gas to hydrogen containing mixtures. Although large fuel processors perform well, small reformers still have some major drawbacks. The object of this invention is to provide an apparatus for the conversion of hydrocarbons to hydrogen rich gas mixtures, that operates at a relatively low temperature, uses air instead of pure oxygen, can be operated at atmospheric pressure, has a low pressure drop, is compact, has low thermal mass and having high thermal efficiency.

Abstract: A novel liquid collector assembly has been developed for a reactor used in the sweetening of sour hydrocarbons (e.g. sour gasoline). This refinery process normally involves contacting a reaction liquid, comprising both aqueous (caustic solution) and organic (hydrocarbon) phases, with a fixed bed of oxidation catalyst. The collector assembly design, comprising a piping manifold and a plurality of dependent, vertically aligned, and perforated conduits, allows for improved separation of the reaction products into essentially pure treated hydrocarbon and spent alkaline reagent streams. If sodium hydroxide is used as caustic solution, for example, the treated hydrocarbon product will normally contain less than 1 ppm by weight of sodium.

Abstract: This invention relates to a sterilisation chamber for use in a sterilisation device or the like, said chamber being adapted to enclose goods to be sterilised during a sterilisation process. The chamber has a self-supported structure being essentially manufactured from a polymeric material.

Abstract: A molding (catalyst structure) for chemical apparatuses which is formed from at least two closed frames and one or more cross-pieces connecting these frames, where the frames are arranged at a distance from one another in a single plane or in a plurality of parallel planes about an (imaginary) molding (structure) axis which is perpendicular to the plane(s) and passes through the center points of the frames. The molding (catalyst structure) is preferably formed from at least four closed frames and one or more cross-pieces connecting these frames, where the frames are arranged one inside the other at a distance from one another in at least two parallel planes about an (imaginary) molding (structure) axis which is perpendicular to the planes and passes through the center points of the frames, and each plane has at least two frames.

Abstract: A method and system for reducing the amount of NOx in an automotive vehicle combustion exhaust gas are disclosed. Accordingly, the system includes a first converter for forming aldehyde in a tributary fluid that includes fuel from the fuel tank of an automotive vehicle. Once the aldehyde is formed, the tributary fluid is combined with combustion exhaust of the vehicle to form an aldehyde/exhaust admixture. Thereafter, a second converter of the system is used to reduce NOx in the aldehyde/exhaust admixture to N2 gas and O2 gas.

Abstract: A catalyst carrier body includes a honeycomb body having sheet-metal layers and an axial extent. The sheet-metal layers are at least partly structured in such a way that the honeycomb body has passages through which an exhaust gas can flow. The sheet-metal layers of the honeycomb body have end regions lying radially outwardly. A tubular jacket has an edge and an axial span shorter than the axial extent of the honeycomb body. The tubular jacket is connected to the honeycomb body in at least one axial partial-region by a joining technique. A sleeve has an axial length shorter than the axial extent of the honeycomb body and is disposed on an outer region of the honeycomb body, in the vicinity of an end surface. The sleeve has an inner shell surface connected by a joining technique to the end regions of the sheet-metal layers at the end surfaces. The honeycomb body projects beyond an edge of the tubular jacket in a projecting section surrounded by the sleeve.

Abstract: The present invention provides a reactor, which includes:

Abstract: The present invention provides a support structure for a catalyst disposed within an outer containment. Several unique arrangements and connections of supporting struts that form the structure provide a number of significant advantages and improvements. The support structure provides a very low disturbance of gas flow while maintaining a high amount of contact support with catalyst foils. In addition to a high tolerance of thermal gradients and fewer stress concentrations, strong support in radial and axial directions is also provided.

Abstract: A catalyst substrate comprises a substrate material having an inlet, an outlet, an opening therebetween to allow for the passage of exhaust gas therethrough, and further comprises a catalyst and a layer of zirconium phosphate. Catalyst substrates coated with zirconium phosphate exhibit improved thermal durability, improved thermal shock resistance, and improved alkali and acidic corrosion resistance.

Abstract: A catalytic converter comprises a catalyst substrate concentrically disposed in a shell and having a mat support material located concentrically in between the catalyst substrate and shell. The catalyst substrate includes structural features located on its outer surface that engage the mat support material. The shear forces exerted between the catalyst substrate and mat support material, in addition to the normally present frictional forces, reduce the axial movement of the catalyst substrate during assembly and operation of the catalytic converter.

Abstract: A catalytic converter is constructed by measuring a substrate to be placed within the outer shell or can, wrapping the substrate in a selected mat and loading the package (mat and substrate) into the can. The can is larger than it will be at completion of manufacture to render such loading easier. Subsequent to loading, the measurement of the substrate is used to direct the degree to which the can is reduced in outside dimension such that a selected annulus is created between the substrate and can, said annulus being occupied by said mat.

Abstract: A pollution control device has a metal housing, a solid pollution control device disposed within the metal housing, and a mounting mat disposed between the pollution control element and the housing for positioning the pollution control element and for absorbing mechanical and thermal shock. The mounting mat includes a layer of intumescent material having at least one insert formed of a resilient, flexible, fibrous non-intumescent material. The insert is positioned along at least a portion of at least one lateral edge of the mounting mat to prevent erosion of the intumescent material and to provide a seal between the pollution control element and the housing.

Abstract: A multilayer intumescent mat or sheet is useful for mounting a pollution control device or as a firestop. In one aspect, the multilayer intumescent sheet of the invention comprises a non-moldable flexible non-intumescent layer and a non-moldable flexible intumescent layer comprising an intumescent material wherein the layers form a single sheet without the use of auxiliary bonding means. The mat desirably includes a significant proportion of inorganic fiber containing shot, and small proportions of shot-free inorganic fiber and intumescent material. In another aspect, the multilayer intumescent sheet of the invention comprises a first non-moldable intumescent layer comprising a first intumescent material and a second non-moldable intumescent layer comprising a second intumescent material, the first and second intumescent materials being different, wherein the layers form a single sheet without the use of auxiliary bonding means.

Abstract: According to the invention, there are provided catalyst carrier 14 for an exhaust gas purification system, and the method therefor. The catalyst carrier 14 has a honeycomb structure formed of a roll of bands of stainless steel-made one corrugated sheet 1 and one plain sheet 2, which hold stainless steel-made bonding assistants 15 therebetween. Said bonding assistants 15 have width narrower than those of said sheets 1,2, wherein they are positioned at locations radially inside the projections 6 formed at side ends of the corrugated sheet 1 and have thickness T greater than height H of projections 6. Thus, corrugated sheet 1 and plain sheet 2 are diffusion bonded to each other with locally centered high contact pressure, without the influence of projections 6.

Abstract: The invention provides an ammonia generating apparatus which is high in efficiency of heat transfer and compact. The ammonia generating apparatus includes a urea water introducing part, a flow passage for urea water to flow therethrough, and heating means, wherein the flow passage is connected to the urea water introducing part, and the heating means heats urea water present within the flow passage.

Abstract: Catalytic converter or diesel particulate filter or trap having edge protectant which reduces erosion of a lateral edge of an intumescent mounting mat when exposed to hot, impinging gases.

Abstract: Fiber-reinforced vehicle interior trim and a method of manufacturing interior trim in a one-step molding process. A skin material and fibrous reinforcement mat are located in a molding tool. A moldable foam-forming material is applied to the tool between the skin material and the fibrous reinforcement mat. The foam-forming material penetrates the mat and expands and cures such that the foam binds to both the skin and the reinforcement mat to produce a molded interior trim piece.

Abstract: A non-intumescent mat for providing a support structure for low temperature fragile structures in exhaust gas treatment devices, such as catalytic converters, diesel particulate traps, and like, comprising amorphous inorganic fibers. The fibers have Young's Modulus of less than about 20×106 psi and a geometric mean diameter less than about 5 &mgr;m. The mat is adapted to provide a holding force of at least 15 psi throughout an average mat temperature range from ambient temperature up to at least about 350° C. The amorphous inorganic fibers are preferably melt formed fibers comprising the fiberization product of a melt comprising alumina/silica.

Abstract: Conduits for a radial flow reactor to provide fluid/solid contacting are improved structurally in terms of possessing good flexibility and a high resistance to vertical buckling when subjected to radially and axially directed stresses. The desired conduit characteristics are obtained using connection flaps to flexibly join a curved profile wire front side to a flatter back side that is proximate to the reactor vessel wall. The rigid profile wire section is maintained at some distance from the vessel wall so that the conduit can flex without permanent damage in an environment where stresses are imparted due to either temperature or thermal expansion differences within the reactor environment. The radial flow reactor of this invention is especially suited for processes such as catalytic reforming where thermally-induced stresses result from both transient and discontinuous operation.

Abstract: A multilayer intumescent mat or sheet is useful for mounting a pollution control device or as a firestop. In one aspect, the multilayer intumescent sheet of the invention comprises a non-moldable flexible non-intumescent layer and a non-moldable flexible intumescent layer comprising an intumescent material wherein the layers form a single sheet without the use of auxiliary bonding means. The mat desirably includes a significant proportion of inorganic fiber containing shot, and small proportions of shot-free inorganic fiber and intumescent material. In another aspect, the multilayer intumescent sheet of the invention comprises a first non-moldable intumescent layer comprising a first intumescent material and a second non-moldable intumescent layer comprising a second intumescent material, the first and second intumescent materials being different, wherein the layers form a single sheet without the use of auxiliary bonding means.

Abstract: An improved catalytic reactor for high temperature reactions having a reaction chamber and a monolithic catalyst structure disposed in the reaction chamber is disclosed wherein the catalyst structure has a multiplicity of longitudinally disposed channels formed by thin metal substrate walls which expand on exposure to the heat generated in high temperature reactions and reactor also includes a monolithic open cellular support structure disposed in the reaction chamber having a multiplicity of longitudinally disposed passageways formed by strips of high temperature resistant metal or ceramic material with the support structure being secured on its outer periphery to the wall of the reaction chamber to limit movement along the longitudinal axis, and being positioned at and abutting against the outlet end of the catalyst structure.

Abstract: A catalytic converter has a ceramic catalytic support, a cylindrical casing for holding the catalytic support therein and a holding member disposed between the catalytic support and the casing. The holding member has a plurality of net-like layers, each of which is parallel to a circumferential surface of the catalytic support and has fibers randomly tangled with each other. Because of this structure, when the catalytic converter is assembled, damage to the fibers and separation of the fibers of the holding member can be prevented. As a result, the holding member can securely and steadily hold the catalytic support within the casing.

Abstract: A catalytic converter for use in the exhaust system of an internal combustion engine, said catalytic converter including a housing having a cavity formed therein and having a gas inlet end and a gas outlet end, a pair of end members, each of said end members having an opening for allowing exhaust gases to pass therethrough, one of said end members sealingly connected to the gas inlet end of said housing and the other of said end members sealingly connected to the gas outlet end of said housing, a catalyst coated substrate located within said cavity and having a gas inlet face and a gas outlet face, a first mat of material which is expandable in an axially direction when heated positioned between said housing and a first portion of the catalyst coated substrate, and a second mat of material which is expandable in a radial direction surrounding a second portion of the catalyst coated substrate.

Abstract: A system for steam reformation of a hydrocarbon includes a combined oxidizer/burner unit connected downstream of a reformer and in thermal contact therewith. The combined unit functions during reformation reaction operation of the reformer as a CO oxidizer and simultaneously as a catalytic burner. During reformation reaction operation, a gas containing oxygen is added to the combined oxidizer/burner unit that has an oxygen component that is greater than the oxygen component required for CO oxidation alone. The system may be used, for example, in fuel-cell-operated motor vehicles to obtain hydrogen from methanol carried in liquid form that is required for the fuel cells.

Abstract: Ceramic honeycombs used as catalyst supports for combustion engine exhaust pollution control are provided with insulating porous refractory thermal barrier coatings disposed on and bonded to at least a portion of the external skins of the honeycombs, reducing the outer barrier coating surface temperature to provide thermal protection for the resilient fiber support materials used to mount the supports in catalytic converter enclosures.

Abstract: The invention provides a multilayer intumescent mat or sheet that is useful as a mounting for a pollution control device or as a firestop. In one aspect, the multilayer intumescent sheet of the invention includes a non-moldable flexible non-intumescent layer and a non-moldable flexible intumescent layer including an intumescent material wherein the layers form a single sheet without the use of auxiliary bonding means. In another aspect, the multilayer intumescent sheet of the invention includes a first non-moldable intumescent layer including a first intumescent material and a second non-moldable intumescent layer comprising a second intumescent material, the first and second intumescent materials being different, wherein the layers form a single sheet without the use of auxiliary bonding means. The invention also provides a pollution control device including a multilayer sheet of the invention disposed between a monolith and a housing.

Abstract: A hhoneycomb body with thermal insulation, preferably for an exhaust gas catalytic converter, includes a plurality of honeycombs and thermal insulation having a plurality of stacked and/or wound insulating sheet layers which are mutually supported by microstructures provided in the insulating sheet layers so that intermediate spaces exist between the insulating sheet layers. The microstructures have a height of from 10 .mu.m to 250 .mu.m. The honeycomb body therefore has only slight heat losses to the environment.

Abstract: An exhaust treatment device for an internal combustion engine includes a generally cylindrical substrate and sealing system which are swaged in place within a one-piece housing. The one-piece housing includes segmented inlet and outlet gas shields and diffusers which are spun from a single piece of tubing which also contains the substrate. The spun inlet and outlet gas shields and diffusers have segmented configurations including multiple concave and convex sections produced by spin-forming of the housing. The exhaust treatment device is assembled without the need for welding or any other high temperature operation.

Abstract: In a reforming reactor suitable particularly for the water vapor reforming of methanol in mobile applications such as vehicles, a reaction space is filled with a catalyst pellet fill and has a movable reaction space wall which exerts a position-fixing pressure onto the catalyst pellet fill. According to the invention, a filling device is provided through which catalyst material can be filled from the outside into the reaction space through a passage opening formed in one of the reaction space walls.

Abstract: A reforming reactor system for water vapor reforming of methanol in fuel-cell operated motor vehicles has a reactor unit with a catalyst-filled reaction space and a particle filter which is arranged in a reformate gas pipe downstream of the reactor unit. The catalyst material is carried in the reaction space by a sieve below which a metallic nonwoven for catching sieved-out fragments and dust particles of the catalyst fill is situated. The particle filter contains a spun steel wool netting and/or several filter steps serially connected behind one another. The particle filter may be arranged to be exchangeable without interrupting the operation of the system. Specifically, a particle filter which has a filter body which can be changed in a gas-tight manner transversely to the gas flow and/or a cyclone filter can be used which has a closing device for the purpose of an emptying of a particle collecting pot which does not interrupt the operation.