Abstract: A metal support for a catalyst is disclosed, which is suitable for use in a catalytic converter for an automobile. The support generally does not interact with the catalyst, even at high temperatures, and the catalyst therefore retains its activity for a long period. The support includes a base metal containing chromium, aluminum and silicon, the remainder of the base metal being mostly iron. The specific percentages of chromium, aluminum, and silicon in the base metal can be varied according to a formula. The base metal is coated with a layer of metallic aluminum. A catalyst is applied to the support, preferably by first coating the support with a layer of alumina, and then impregnating the alumina layer with a suitable combustion catalyst. The support can be rolled down to foil thickness. When formed as a foil, the support is particularly useful in making catalytic converters for automobiles. The formula disclosed shows how aluminum or silicon can be substituted for some of the chromium in the base metal.

Abstract: The purpose of this invention is to store hydrogen in the form of a metal hydride. The hydride is disposed on the surface of a plurality of metal fins which are attached to heat transfer tubes. The fins are closely spaced so that the weight of hydrogen stored per unit volume is high, approaching one pound per cubic foot. Because the formation of a metal hydride is quite exothermic, the rate of addition or removal of hydrogen to or from the hydride is limited by the ability of the apparatus to conduct heat to or from the hydride. The structure of the present invention provides for rapid heat transfer, so that the cell can be used in a heat pump, a hydrogen compressor, or to store hydrogen fuel for a vehicle. The invention includes embodiments wherein the heat transfer medium is either a liquid or a gas. The invention also comprises a new method of applying a metal or metal alloy, capable of forming a metal hydride, to a metal surface.

Abstract: A spiral-wound metal catalyst support is disclosed, wherein the layers of the spiral cannot telescope outwardly in either direction. The support is formed by first winding together a flat strip and a corrugated strip, the strips being wound on a mandrel. The mandrel is removed to leave an axial hole. The catalyst support is then flattened at each end, so as to close the axial hole at each end. The flattening is done in mutually perpendicular directions, so that the catalyst support has tapers in both of two directions. The tapers prevent telescoping of the layers of the support. The catalyst support can be placed in a tube before it is flattened, and then the tube and the support can be flattened together, so that the support becomes firmly anchored in the tube. In an alternative embodiment, a second, tapered mandrel is inserted into the support before flattening, the tapered mandrel having a shape conforming to the inner cavity defined by the flattened support.

Abstract: A catalytic converter for a diesel engine comprises a stack of metal strips, coated with a combustion catalyst, the strips being spaced apart by indentations. The indentations are aligned transversely to the flow axis of the converter, and are staggered so that the exhaust gas follows a tortuous path as it flows between the strips. Particulates in the exhaust gas are trapped out in the clefts formed where an indentation presses against the adjacent strip. At intervals, fuel is injected into the exhaust gas. The fuel burns on the catalyzed surface and heats the converter sufficiently to burn the trapped particulates. In an alternative embodiment, there are two converters, and fuel is automatically injected into that converter which has more trapped particulates, so as to burn the particulates trapped in that converter.

Abstract: The catalytic converter comprises a metal honeycomb catalyst support which is anchored in a canister so that it cannot telescope or blow out. The honeycomb catalyst support is formed by folding a strip of metal back and forth upon itself. There are slots in the strip along the lines of folding. When the strip is folded to form the honeycomb, the slots become notches, the notches being aligned so as to define grooves on the periphery of the honeycomb. The canister has internal ridges that mate with the grooves on the honeycomb and anchor the honeycomb.

Abstract: The combustor comprises a single sheet of metal coated with catalyst and wound into a spiral. There is a single spiral passage leading into the core of the spiral. The fuel-air mixture burns on the catalyzed surface of the spiral, and heat is transferred through the metal wall of the spiral to the incoming fuel-air mixture. The incoming fuel-air mixture is preheated to a temperature sufficient to start the catalytic combustion. The fuel content in the mixture can be below the flammability limit. The combustor is compact so that it can be used as a catalytic air preheater in a downhole steam generator.

Abstract: A combustor for generating a mixture of steam and combustion gas is located downhole in an oil well, so that the mixture can be injected directly into the reservoir, to displace heavy oil from the reservoir. The combustion is built up in stages, with each stage supplying hot air to the following stage. The first stage comprises a catalytic heat exchanger, which preheats the incoming air. One side of the exchanger is coated with catalyst. On this side of the exchanger the preheated air burns a clean fuel, so that heat flows through the metal wall of the exchanger to preheat the incoming air. The heated air from the first stage is used to ignite and burn a heavy fuel such as crude oil, which is burned in the second stage and following stages.

Abstract: The catalytic creosote burner comprises a nest of metal plates spaced so that flue gas can flow between the plates. The plates are coated with a catalyst for burning creosote. The plates converge in the direction of the gas flow. There is an advantage in this configuration of converging plates. The frontal area of the burner that faces the fire is increased, so that the burner receives additional heat by radiation from the fire. The frontal area that faces the flue is reduced so that less heat is lost by radiation from the burner. As a result, the burn up of creosote is higher than when the plates are parallel, at the original inlet spacing.

Abstract: A honeycomb catalyst support is formed by folding a single strip of metal back and forth upon itself. Each layer in the honeycomb has indentations of uniform height, so that the spacing between layers is equal to this height. A different pattern of indentations is used in alternate layers, and the indentations are on opposite sides of the strip in alternate layers. This prevents the indentations in successive layers from coinciding and nesting together.

Abstract: A catalytic combustor for generating a mixture of steam and combustion gas is located downhole in an oil well, so that the gas mixture can be injected directly into the oil reservoir to displace heavy oils from the reservoir. There can be a single stage of catalytic combustion, or there can be a stage of thermal combustion followed by a catalytic stage. In either case the purpose of the catalyst is to drive the combustion to completion so that the gas mixture contains no soot that would plug the face of the reservoir.

Abstract: A compact catalytic combustor for generating steam downhole in an oil reservoir has steam generating tubes that are attached to a metal catalyst support. The metal support comprises sheets of metal that are spaced apart and transverse to the tubes. Heat from combustion is generated on the metal sheets and is conducted to the steam generating tubes. The steam is injected into the oil reservoir. The combustion gas is vented to ground level.

Abstract: A metal honeycomb catalyst support is formed by stacking flat strips of metal into a cylindrical shell. The shell is divided by a partition along the axis of the shell. The strips are stacked parallel to the partition. The partition insures that the strips lie flat and are tightly compacted. Indentations in the strips maintain the spacing between the strips. The present invention provides an economical method for making small numbers of honeycombs, which method does not require the use of expensive machinery.

Abstract: The catalyst support is a spiral formed by winding a single strip of metal upon itself. Indentations in the strip maintain a uniform spacing between the layers in the spiral. The indentations are displayed along the strip in at least two different patterns. Different patterns are wound onto successive layers in the spiral so that the indentations in successive layers cannot coincide and nest together.

Abstract: A catalyst support comprises a stack of metal strips, said strips being coated with a catalyst material. Indentations in the strips maintain uniform spacing between the strips, so that gas can flow between the strips. The indentations are spaced so that the indentations in adjacent strips cannot coincide and nest together, so that adjacent strips cannot collapse together.

Abstract: The catalyst support is a spiral formed by winding a single strip of metal upon itself. Indentations in the strip maintain a uniform spacing between the layers in the spiral. Heretofore this uniform spacing has been obtained only by winding a double layer of two strips, one flat and one corrugated.