Abstract: Described herein are improved chemical reactors for carrying out partial oxidation reactions. The chemical reactor permits the use of levels of oxygen above the lower explosion limit (LEL) typically used in partial oxidation reactions, which increases both volumetric reactivity and conversion per pass, resulting in reduced separation and reactant recycle costs. Also described are methods of using the reactors.

Abstract: Described is an industrial scale chemical reactor or reactor containing a shell having an inner wall, and at least one channel inside the shell. The shell has a circular, square, or rectangular cross-sectional area. All of the internal dimensions of the channel are greater than 10 mm, and optionally less than 50 mm. The channel has a rectangular cross-sectional area, and contains a catalyst bed containing catalyst particles and/or pieces containing catalyst particles packed inside the channel. The reactor has improved shell volume utilization, catalyst loading capacities, heat exchange efficiency, process intensification, or combinations thereof, compared to currently existing reactors. Exothermic reactions, such as the Fischer-Tropsch synthesis can be performed inside the channels of the reactor. Also described are methods of making the reactor.

Abstract: Battery packs for high energy density batteries (cells), particularly arrays of such batteries are described herein. The battery packs include a microfibrous media (MFM)-phase change materials (PCM) composite block and one or more active cooling structures. The MFM is typically sintered to the active cooling structures. The battery packs may contain more than one MFM-PCM composite block. Additionally or alternatively, the MFM-PCM composite block may contain different layers containing different MFM-PCM composites, which have different functionalities. In a preferred embodiment, at least one layer contains a flame retardant PCM, while at least one other layer contains a PCM with a lower melting temperature. The cells may be arranged in a repeating square or equilateral triangle pattern, with one or more active cooling structures in the geometric center of the square or triangle.

Abstract: Methods and devices for directly measuring the degree of saturation or degree of deactivation of an adsorbent and/or catalytic bed are described herein. The devices contain an inlet, an outlet, a catalytic and/or adsorbent bed, and optionally a support bed for supporting the catalytic and/or adsorbent bed. The devices further contain one or more structures attached to the reactor that allow for insertion of one or more sensors into the reactor. The sensor is used to spectroscopically interrogate the adsorbent and/or catalyst in situ, providing real-time information regarding adsorbant saturation and/or catalyst deactivation. The devices and methods described herein can be used to determine the saturation degree of adsorbent materials or catalyst beds that are involved in gas-liquid and liquid-liquid heterogeneous systems, such as those used in scrubbing and extraction.

Abstract: Catalysts for oxidative sulfur removal and methods of making and using thereof are described herein. The catalysts contain one or more reactive metal salts dispersed on one or more substrates. Suitable reactive metal salts include those salts containing multivariable metals having variable valence or oxidation states and having catalytic activity with sulfur compounds present in gaseous fuel streams. In some embodiments, the catalyst contains one or more compounds that function as an oxygen sponge under the reaction conditions for oxidative sulfur removal. The catalysts can be used to oxidatively remove sulfur-containing compounds from fuel streams, particularly gaseous fuel streams having high sulfur content.

Abstract: Improved methods for preparing highly porous mesh media and loading functional particles into the media are described herein. The highly porous media can be used as supports for catalyst materials for a variety of applications, such as desulfurization. Pre-manufactured catalyst can be loaded into the sintered open media. Thus, the contamination issues associated wetlay paper making and pre-oxidation, the deactivation issues associated with the sintering and pre-oxidation steps, and the corrosion issues associated with the catalyst formation step can be avoided. The methods described herein result in the formation of highly porous media with functional particles immobilized inside.

Abstract: Methods for improving heat transfer at the interface between the internal reactor wall and mesh media containing microfibrous entrapped catalysts (MFECs) and/or microfibrous entrapped sorbents (MFESs) are described herein. Improved (e.g., more rapid) heat transfer can be achieved using a variety of approaches including increasing the contacting area of the interface between the mesh media and the reactor wall so that more contacting points are formed, enhancing the contacting efficiency at the contacting points between the mesh media and the reactor wall, increasing the number of contact points between the mesh media and the reactor wall using fine fibers, and combinations thereof.

Abstract: Thermal management systems for high energy density batteries, particularly arrays of such batteries, and methods of making and using thereof are described herein. The system includes one or more thermal conductive microfibrous media with one or more phase change materials dispersed within the microfibrous media and one or more active cooling structures. Energy storage packs or arrays which contain a plurality of energy storage cells and the thermal management system are also described. Further described are thermal or infrared shielding blankets or barriers comprising one or more thermal conductive microfibrous media comprising one or more phase change materials dispersed within the microfibrous media.

Abstract: Catalysts for oxidative sulfur removal and methods of making and using thereof are described herein. The catalysts contain one or more reactive metal salts dispersed on one or more substrates. Suitable reactive metal salts include those salts containing multivariable metals having variable valence or oxidation states and having catalytic activity with sulfur compounds present in gaseous fuel streams. In some embodiments, the catalyst contains one or more compounds that function as an oxygen sponge under the reaction conditions for oxidative sulfur removal. The catalysts can be used to oxidatively remove sulfur-containing compounds from fuel streams, particularly gaseous fuel streams having high sulfur content.

Abstract: A vessel packed with a microfibrous media made of micron-sized highly conductive fibers, which are able (and may be used) to immobilize various reactive materials including catalysts, sorbents, electrocatalysts, and other chemically reactive solids. The vessel enables fine temperature control and a uniform temperature profile for a range of highly endothermic or exothermic chemical reactions, sorptions, separation processes, mixing operations, and heat transfer applications.