Abstract: A reactor installation tool and method for installing a reactor unit in a reactor tube. A reactor installation tool including a movable assembly and a fixed assembly linked together such that the movable assembly can be adjusted relative to the fixed assembly. The movable assembly including a reactor sleeve attachment means for releasably securing a reactor sleeve loaded with a reactor unit to the tool. The fixed assembly including an expandable clamping unit for releasably securing the tool to a reactor tube. A reactor unit can be installed in the reactor tube by adjusting the movable assembly to extract the reactor unit from the reactor sleeve as the fixed assembly is rigidly secured to the reactor tube. The fixed assembly can be released from the reactor tube and the reactor installation tool can be removed from the reactor tube.

Abstract: A monolith for catalytic or sorbent purposes. The monolith includes a substrate sheet having attached thereto a plurality of catalytic or sorbent beads. Each bead has a diameter of at least fifty microns. The substrate sheet at least partially defines one or more channels through the monolith. Fluid flowing through the channels will contact the beads for catalytic or sorbent purposes.

Abstract: A reactor for carrying out catalytic reactions. The reactor includes a reactor component optionally arranged on a central rod in a reactor tube. The reactor component can have fluid ducts for directing fluid flow through the reactor. The fluid ducts are effective for increasing heat transfer in the reactor. The reactor component can further have a washer attached to a top or bottom surface for directing fluid flow.

Abstract: A low-cost, high-temperature heat exchanger is made from a notched piece of metal, the metal being folded back and forth upon itself to form a monolith. The notches in the metal piece create openings, communicating with distinct sides of the monolith. Ducts are attached to the openings. Cut pieces of corrugated metal, which may have a catalyst coating, are inserted between folds of the monolith. The heat exchanger may be used as part of a fuel cell system, or in other industrial applications, to recover waste heat, or to conduct various catalytic and non-catalytic reactions. The invention also includes an element, or building block, for a high-temperature heat exchanger, including a folded metal monolith with metal combs inserted, the monolith and the combs defining seams which are hermetically sealed.

Abstract: A reactor including a monolith having a plurality of fins in an annular arrangement for receiving fluid flow through the reactor. The monolith is disposed within a generally cylindrical outer tube, and around a corrugated inner tube. The reactor includes a device for urging the monolith radially outward, so as to maintain contact between the monolith and the outer tube.

Abstract: A reactor including a monolith having a plurality of fins in an annular arrangement for receiving fluid flow through the reactor. The monolith is disposed within a generally cylindrical outer tube, and around a corrugated inner tube. The reactor includes a device for urging the monolith radially outward, so as to maintain contact between the monolith and the outer tube.

Abstract: A reactor includes a plurality of metal leaves which extend from an interior of the reactor to its exterior. The leaves occupy a space between an internal mandrel and an external tube. In one embodiment, the leaves are generally flat pieces of foil, stacked together so that they do not touch except at spacers formed in the pieces. In another embodiment, the leaves are formed of a pleated and crimped foil, each leaf being defined by a piece of foil that has been folded over upon itself. In both embodiments, the leaves extend from the internal mandrel, radially outward to an inner surface of the tube. The reactor facilitates the transfer of heat between the outside of the reactor and its inside region.

Abstract: A low-cost, high-temperature heat exchanger is made from a notched piece of metal, the metal being folded back and forth upon itself to form a monolith. The notches in the metal piece create openings, communicating with distinct sides of the monolith. Ducts are attached to the openings. Cut pieces of corrugated metal, which may have a catalyst coating, are inserted between folds of the monolith. The heat exchanger may be used as part of a fuel cell system, or in other industrial applications, to recover waste heat, or to conduct various catalytic and non-catalytic reactions. The invention also includes an element, or building block, for a high-temperature heat exchanger, including a folded metal monolith with metal combs inserted, the monolith and the combs defining seams which are hermetically sealed.

Abstract: A low-cost, high-temperature heat exchanger is made from a notched piece of metal, the metal being folded back and forth upon itself to form a monolith. The notches in the metal piece create openings, communicating with distinct sides of the monolith. Ducts are attached to the openings. Cut pieces of corrugated metal, which may have a catalyst coating, are inserted between folds of the monolith. The heat exchanger may be used as part of a fuel cell system, or in other industrial applications, to recover waste heat, or to conduct various catalytic and non-catalytic reactions. The invention also includes an element, or building block, for a high-temperature heat exchanger, including a folded metal monolith with metal combs inserted, the monolith and the combs defining seams which are hermetically sealed.

Abstract: A reactor cartridge includes a plurality of spaced-apart monoliths, formed along a tube or other mandrel. Each monolith is formed of a pair of flat and corrugated metal strips, spirally wound around the tube. These strips could be made of solid or screen material. The corrugations are skewed, such that the monolith imparts a swirl to gases flowing through it. The corrugations of the strips in adjacent monoliths are oriented differently, so that successive monoliths impart different swirls to the gases, so as to promote mixing of gases and better heat transfer from the exterior to the interior of the cartridge. An insertion and removal tool simplifies the procedure for stacking such cartridges in a long pipe, or for removing cartridges from the pipe. The all-metal construction facilitates heat transfer through the entire reactor, and avoids the problems associated with packed ceramic beds.

Abstract: A fuel cell system includes a fuel cell stack, a reformer which is thermally integrated with the fuel cell stack. The system may also include a combustor which is thermally integrated with the reformer. The reformer is a reformation catalyst containing channel bounded by at least one corrugated foil wall. The reformer is adapted to reform a hydrocarbon fuel to a hydrogen containing reaction product and to provide the reaction product to the fuel cell stack.

Abstract: A catalytic reactor or heat exchanger includes a monolith defining a plurality of leaves, the monolith having a generally annular cross-section. The monolith is disposed within a generally cylindrical outer tube, and around a corrugated inner tube. The reactor includes a device for urging the monolith radially outward, so as to maintain contact between the monolith and the outer tube. Such device may include a coned washer, or it may be defined by a folded flap that is integral with the inner tube. In either case, the reactor compensates for metal creep, and virtually insures continued contact between the monolith and the outer tube.

Abstract: In a downhole steam generator, hydrogen, oxygen, and water are separately injected into an oil well. The hydrogen and oxygen are made to react, either with the aid of a catalyst or due to an electric spark. Heat from the reaction converts the water in the area into steam, which is then used to enhance the production of the oil well. The hydrogen may be produced at the surface of the well by the steam reforming of a hydrocarbon. The hydrogen injected into the well may be provided as part of a reformate mixture produced by the steam reforming process. The water is preferably atomized by the stream of oxygen immediately before ignition, so as to provide a maximum surface area for heat absorption.

Abstract: A reactor cartridge includes a plurality of spaced-apart monoliths, formed along a tube or other mandrel. Each monolith is formed of a pair of flat and corrugated metal strips, spirally wound around the tube. These strips could be made of solid or screen material. The corrugations are skewed, such that the monolith imparts a swirl to gases flowing through it. The corrugations of the strips in adjacent monoliths are oriented differently, so that successive monoliths impart different swirls to the gases, so as to promote mixing of gases and better heat transfer from the exterior to the interior of the cartridge. An insertion and removal tool simplifies the procedure for stacking such cartridges in a long pipe, or for removing cartridges from the pipe. The all-metal construction facilitates heat transfer through the entire reactor, and avoids the problems associated with packed ceramic beds.

Abstract: A reactor including a monolith having a plurality of fins in an annular arrangement for receiving fluid flow through the reactor. The monolith is disposed within a generally cylindrical outer tube, and around a corrugated inner tube. The reactor includes a device for urging the monolith radially outward, so as to maintain contact between the monolith and the outer tube.

Abstract: A low-cost, high-temperature heat exchanger is made from a notched piece of metal, the metal being folded back and forth upon itself to form a monolith. The notches in the metal piece create openings, communicating with distinct sides of the monolith. Ducts are attached to the openings. Cut pieces of corrugated metal, which may have a catalyst coating, are inserted between folds of the monolith. The heat exchanger may be used as part of a fuel cell system, or in other industrial applications, to recover waste heat, or to conduct various catalytic and non-catalytic reactions. The invention also includes an element, or building block, for a high-temperature heat exchanger, including a folded metal monolith with metal combs inserted, the monolith and the combs defining seams which are hermetically sealed.

Abstract: In a downhole steam generator, hydrogen, oxygen, and water are separately injected into an oil well. The hydrogen and oxygen are made to react, either with the aid of a catalyst or due to an electric spark. Heat from the reaction converts the water in the area into steam, which is then used to enhance the production of the oil well. The hydrogen may be produced at the surface of the well by the steam reforming of a hydrocarbon. The hydrogen injected into the well may be provided as part of a reformate mixture produced by the steam reforming process. The water is preferably atomized by the stream of oxygen immediately before ignition, so as to provide a maximum surface area for heat absorption.

Abstract: A catalyst support is formed of a monolith having corrugated metal leaves. The corrugations of each leaf are oblique relative to the edges of the leaf. Each leaf extends from an interior region to an exterior region, and has corrugations that are non-parallel to the corrugations in an adjacent leaf. Each leaf also includes slits, and is coated with a suitable catalyst. A set of monoliths, made as described above, are stacked within a cylindrical pipe. The corrugations define gas flow channels, which enable heat applied to the exterior of the pipe to travel to the center of the monolith, and back to the outside. The support of the present invention thus facilitates heat transfer to essentially all regions of the monolith. The invention also inherently overcomes the problem associated with thermal mismatch between the metal pipe and a ceramic catalyst material.