Abstract: A method and apparatus for generating transpiration cooling using an oxidized porous HTA layer metallurgically bonded to a substrate having micro-channel architectures. The method and apparatus generates a porous HTA layer by spreading generally spherical HTA powder particles on a substrate, partially sintering under O2 vacuum until the porous HTA layer exhibits a porosity between 20% and 50% and a neck size ratio between 0.1 and 0.5, followed by a controlled oxidation generating an oxidation layer of alumina, chromia, or silica at a thickness of about 20 to about 500 nm. In particular embodiments, the oxidized porous HTA layer and the substrate comprise Ni as a majority element. In other embodiments, the oxidized porous HTA layer and the substrate further comprise Al, and in additional embodiments, the oxidized porous HTA layer and the substrate comprise ?-Ni+??-Ni3Al.

Abstract: The disclosure provides a method for the production of composite particles utilizing a mechano chemical bonding process following by high energy ball milling on a powder mixture comprised of coating particles, first host particles, and second host particles. The composite particles formed have a grain size of less than one micron with grains generally characterized by a uniformly dispersed coating material and a mix of first material and second material intermetallics. The method disclosed is particularly useful for the fabrication of oxide dispersion strengthened coatings, for example using a powder mixture comprised of Y2O3, Cr, Ni, and Al. This particular powder mixture may be subjected to the MCB process for a period generally less than one hour following by high energy ball milling for a period as short as 2 hours. After application by cold spraying, the composite particles may be heat treated to generate an oxide-dispersion strengthened coating.

Abstract: This disclosure addresses the issue of providing a metallic-ceramic overlay coating that potentially serves as an interface or bond coat layer to provide enhanced oxidation resistance to the underlying superalloy substrate via the formation of a diffusion barrier regime within the supporting base material. Furthermore, the metallic-ceramic coating is expected to limit the growth of a continuous thermally grown oxide (TGO) layer that has been primarily considered to be the principal cause for failure of existing TBC systems. Compositional compatibility of the metallic-ceramic with traditional yttria-stabilized zirconia (YSZ) top coats is provided to further limit debond or spallation of the coating during operational use. A metallic-ceramic architecture is disclosed wherein enhanced oxidation resistance is imparted to the surface of nickel-based superalloy or single crystal metal substrate, with simultaneous integration of the yttria stabilized zirconia (YSZ) within the metallic-ceramic overlayer.

Abstract: A catalytic combustor (14) includes a first catalytic stage (30), a second catalytic stage (40), and an oxidation completion stage (49). The first catalytic stage receives an oxidizer (e.g., 20) and a fuel (26) and discharges a partially oxidized fuel/oxidizer mixture (36). The second catalytic stage receives the partially oxidized fuel/oxidizer mixture and further oxidizes the mixture. The second catalytic stage may include a passageway (47) for conducting a bypass portion (46) of the mixture past a catalyst (e.g., 41) disposed therein. The second catalytic stage may have an outlet temperature elevated sufficiently to complete oxidation of the mixture without using a separate ignition source. The oxidation completion stage is disposed downstream of the second catalytic stage and may recombine the bypass portion with a catalyst exposed portion (48) of the mixture and complete oxidation of the mixture.

Abstract: A catalytic combustor (28) includes a plurality of concentric tubular pressure boundary elements (46). The pressure boundary elements are arranged to form a first annular space (e.g., 50) conducting a first fluid flow (e.g., 60) and a second annular space (e.g. 49), separate from the first annular space, conducting a second fluid flow (e.g., 58). A catalytic material (32) is disposed on a surface (e.g., 64) of at least one of the pressure boundary elements and exposed to at least one of the fluid flows.

Abstract: A catalytic combustor for a combustion turbine that employs a protective nickel aluminide diffusion barrier on its inside and outside surfaces with a porous alumina, zirconia, titania, and/or ceria, and bond phase coating on the outside surface in which a catalyst is contained.

Abstract: A high temperature hydrogen gas separation membrane employing a physically interlocking barrier layer to form a spinel or intermetallic architecture bonding the metal barrier layer onto the surface of a fibrous metal medial structural support substrate. A tantalum/niobium interface layer is deposited on the barrier layer. The final layer is a precious metal such as palladium, which is deposited on the tantalum/niobium interface layer.

Abstract: An improved metal gas separation membrane for separating hydrogen from a gas steam includes a quantity of metal particles that are bonded together to form a porous body that is selectively permeable to hydrogen. The porous body may have a porosity that increases from a first surface to an opposite second surface. The metal gas separation membrane may additionally include a coating of ceramic particles on the first surface thereof to further decrease the porosity at the first surface. Alternatively, or in addition thereto, the metal gas separation membrane may include a thin foil or coating of a dense precious metal such as palladium, palladium-alloys, and the like applied thereto that is permeable by hydrogen according to a chemisorption-dissociation-diffusion transport phenomenon.

Abstract: An improved metal gas separation membrane for separating hydrogen from a gas steam includes a quantity of metal particles that are bonded together to form a porous body. The porous body may have a porosity that increases from a first surface to an opposite second surface and may additionally include a coating of ceramic particles on the first surface. The metal gas separation membrane may include a coating of a dense precious metal applied thereto that is permeable by hydrogen via chemisorption-dissociation-diffusion. The porous body may include a catalytic enhancement. Also disclosed are three gas separation modules that employ the metal gas separation membrane disposed within a core of the gas separation module for separating hydrogen from a gas stream. The gas separation membranes are each supported on a first mounting member and a second mounting member. The gas separation modules may also include a catalytic enhancement.

Abstract: A hot gas filtration apparatus includes a vessel, a plurality of filter elements mounted within the vessel and positioned such that hot gas flows through said filter elements, with each of said filter elements having a porous body, and a catalytic layer on surfaces of the porous body. The porous body of the filter element may include one of: a porous ceramic monolithic matrix, a continuous fiber reinforced ceramic composite (CFCC) matrix, a metallic matrix, an intermetallic matrix, a superalloy, and a metal-ceramic composite matrix. When the porous body is a nonoxide ceramic, a metallic matrix, an intermetallic matrix, a superalloy, or a metal-ceramic composite matrix, the invention further includes an oxidative resistant layer coating surfaces within the porous body, and the catalytic layer is on the oxidative resistant layer. A porous particulate removal membrane can be positioned on one or more surfaces of the filter element. The porous membrane can also provide a surface for one or more catalysts.

Abstract: An apparatus 20 may include a generator 22 and a combustion turbine 24 for driving the generator, the combustion turbine having an air inlet 40 for receiving an inlet air flow. The apparatus may also include an inlet air flow sampling sensor 26. The inlet air flow sampling sensor 26, in turn, may include a solution container 46 for containing a solution 50 for sampled air from the inlet air flow. The inlet air flow sampling sensor 26 additionally may include sensing circuitry for sensing at least one dissolved material in the solution 50. For example, the material may be salt, such as found in the inlet air for coastal power plants.

Abstract: An improved metal catalytic tube includes an elongated metal member formed at least partially of metal particles and including a catalytic enhancement incorporated into the metal member. The metal member is formed with a cavity and includes an inner surface defined by the cavity and an outer surface opposite the inner surface. The metal member has a porosity at the outer surface that is greater than the porosity at the inner surface. The porosity at the inner surface is sufficiently low that the metal member can carry a quantity of gas through the cavity without the gas leaking through the inner surface of the metal member. The abstract shall not be used for interpreting the scope of the claims.

Abstract: A catalytic combustor includes a plurality of rectangular, tubular subassemblies having the catalyst coating on their outside surfaces. The subassemblies are held in spaced relationship within channels in support walls so that the catalyst coated surfaces of adjacent subassemblies define a catalyst-coated channel, and the interior of the tubular subassemblies defines uncoated channels. This structure permits precise location and support for the various subassemblies, provides wide flexibility in selecting the number and size of catalyst coated subassemblies, and provides for multiple possible flow paths for cooling air and fuel-air mixture through the catalytic combustor.

Abstract: A combined hot gas cleanup system and gas separation unit is contained within a single pressure vessel. Preferably, the combined unit is an integral structure that is retrofittable to replace existing candle filters in their installed holders. The integral unit can be replaced to adapt the combined system for different applications.

Abstract: A catalytic combustor includes a plurality of rectangular, tubular subassemblies having the catalyst coating on their outside surfaces. The subassemblies are held in spaced relationship within channels in support walls so that the catalyst coated surfaces of adjacent subassemblies define a catalyst-coated channel, and the interior of the tubular subassemblies defines uncoated channels. This structure permits precise location and support for the various subassemblies, provides wide flexibility in selecting the number and size of catalyst coated subassemblies, and provides for multiple possible flow paths for cooling air and fuel-air mixture through the catalytic combustor.

Abstract: A combined hot gas cleanup system and gas separation unit is contained within a single pressure vessel. Preferably, the combined unit is an integral structure that is retrofittable to replace existing candle filters in their installed holders. The integral unit can be replaced to adapt the combined system for different applications.

Abstract: A gasket (1) is made by repetitively spirally winding a fiber (3) back on itself in a closed path. The gasket (1) so made has a multi-layer spiral winding (1) formed in a loop (5). The fiber (3) can be wound at a constant wrap rate to form a gasket with a uniform cross-section around the loop. Alternatively, the wrap rate can be varied, increased to increase cross-sectional bulk, and decreased to reduce cross-section bulk around the loop (5). Also, the spiral winding (7) can be applied over a core (13) of either strands of the fiber (3) or a dissimilar material providing a desired property such as resiliency, stiffness or others. For high temperature applications, a ceramic fiber (3) can be used. The gasket (1) can have any of various geometric configurations with or without a core (13).

Abstract: A filter holder assembly is provided that utilizes a fail-safe regenerator unit with an annular spacer ring having an extended metal collar for containment and positioning of a compliant ceramic gasket used in the assembly. The filter holder assembly is disclosed for use with advanced composite, filament wound, and metal candle filters.

Abstract: An improved metal gas separation membrane for separating hydrogen from a gas steam includes a quantity of metal particles that are bonded together to form a porous body that is selectively permeable to hydrogen. The porous body may have a porosity that increases from a first surface to an opposite second surface. The metal gas separation membrane may additionally include a coating of ceramic particles on the first surface thereof to further decrease the porosity at the first surface. Alternatively, or in addition thereto, the metal gas separation membrane may include a thin foil or coating of a dense precious metal such as palladium, palladium-alloys, and the like applied thereto that is permeable by hydrogen according to a chemisorption-dissociation-diffusion transport phenomenon.

Abstract: An improved metal gas separation membrane for separating hydrogen from a gas steam includes a quantity of metal particles that are bonded together to form a porous body. The porous body may have a porosity that increases from a first surface to an opposite second surface and may additionally include a coating of ceramic particles on the first surface. The metal gas separation membrane may include a coating of a dense precious metal applied thereto that is permeable by hydrogen via chemisorption-dissociation-diffusion. The porous body may include a catalytic enhancement. Also disclosed are three gas separation modules that employ the metal gas separation membrane disposed within a core of the gas separation module for separating hydrogen from a gas stream. The gas separation membranes are each supported on a first mounting member and a second mounting member. The gas separation modules may also include a catalytic enhancement.