US-12623210-B2 - Compositions, methods, and apparatuses for catalytic combustion

Abstract

There is provided a catalyst composition including a hydrogen oxidation catalyst and an oxygen reduction catalyst. Heat exchange reactors including the catalyst are also provided. The catalyst is adapted for low temperature activation of a hydrogen combustion reaction.

Inventors

• Steven James HEATON
• Samuel James KIRK

Assignees

• Star Scientific Limited

Dates

Publication Date

20260512

Application Date

20221228

Claims (17)

1. 1 . A reactor apparatus comprising: a heating element comprising a plurality of plates, each plate comprising a catalytic surface having a catalyst composition applied thereon, the catalyst composition for catalytically combusting a hydrogen fuel, wherein the catalytic surface comprises a first phase including a hydrogen oxidation catalyst (HOC) and a second phase including an oxygen reduction catalyst (ORC); and a combustion cavity between each two adjacent plates; a conduit in contact with the plurality of plates, the conduit including: an inlet for receiving a heat exchange medium, and an outlet; and a shell surrounding the conduit and the heating element, the shell having one or more inlets for receiving the hydrogen fuel and an oxidizer; wherein energy released by the catalytic combustion of the hydrogen fuel is transferred to the heat exchange medium; wherein the catalyst composition is adapted to lower the activation energy of the combustion of the hydrogen fuel such that the reaction occurs under low temperatures; and wherein the heat exchange medium comprises water.
2. 2 . The reactor of claim 1 , wherein the plurality of plates are stacked.
3. 3 . The reactor of claim 2 , wherein one or more of the plurality of plates is corrugated.
4. 4 . The reactor of claim 1 , wherein the conduit is positioned between two adjacent plates.
5. 5 . The reactor of 4 , wherein the conduit weaves between two adjacent plates.
6. 6 . The reactor of claim 1 , further comprising a lumen or groove at a contact point between two adjacent plates, the lumen or groove for receiving the conduit.
7. 7 . The reactor of claim 1 , wherein adjacent plates are spaced apart by a joint member.
8. 8 . The reactor of claim 7 , wherein the joint member has a lumen or groove for receiving the conduit.
9. 9 . The reactor of claim 1 , comprising a combustion cavity between two adjacent plates.
10. 10 . The reactor of claim 9 , further comprising one or more distributor for distributing the fuel and the oxidizer to the combustion cavity proximate to the plurality of plates.
11. 11 . The reactor of claim 10 , wherein the one or more distributor comprises a first distributor for distributing the fuel and a second distributor for distributing the oxidizer.
12. 12 . The reactor of claim 11 , wherein mixing of the fuel and the oxidizer occurs in the combustion cavity.
13. 13 . The reactor claim 1 , wherein the catalytic surface includes an HOC area and an ORC area having a ratio of between about 9:1 and about 4:1.
14. 14 . The reactor of claim 13 , wherein the ratio of the HOC area to the ORC area is about 20:3.
15. 15 . The reactor of claim 1 , further comprising a preheater upstream of and in thermal contact with the reactor, for preheating the heat exchange medium or the fuel mixture.
16. 16 . The reactor of claim 1 , wherein the transfer of the energy to the water effects vaporization to produce steam.
17. 17 . The reactor of claim 1 , wherein the heating element is modular.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a divisional of U.S. patent application Ser. No. 16/641,439, filed Feb. 24, 2020, which is a national phase application under 35 U.S.C. § 371 of International Application No. PCT/AU2018/050895 filed 22 Aug. 2018, which claims priority to U.S. Provisional Application No. 62/549,816, filed 24 Aug. 2017. The entire contents of each of the above-referenced disclosures are specifically incorporated by reference herein without disclaimer. FIELD The invention relates to the catalytic combustion of fuel mixtures. In particular, the invention relates to the catalytic combustion of clean fuel mixtures. BACKGROUND Various fuels have been used to harness energy. Traditionally, the majority of fuels are derived from fossil fuels. However, the use of fossil fuels may result in the generation of emissions of carbon dioxide and other greenhouse gases. There is growing evidence that these emissions may contribute to anthropogenic climate change, and to a decrease in overall air quality. In response to these findings, efforts have been made to shift sources of energy from fossil fuels to fuels derived from cleaner sources. For example, coal fired equipment has been shut down in many nations in order to reduce emissions to improve air quality. This equipment may be found, for example, in power plants or district heating plants. These plants may contain other equipment, such as steam equipment and/or turbines, which may be converted for use with other fuels to generate electricity or heating. One potential source of clean energy is hydrogen. Hydrogen may be produced in a number of ways, including steam reformation or electrolysis. When the electricity for electrolysis is derived from clean sources, such as nuclear, wind, tidal, or solar, the hydrogen produced does not result in the generation of carbon emissions. Hydrogen reacts with oxygen to form water and releases energy. This reaction has been used by fuel cells to directly generate electricity. However, factors such as the degradation of membranes and complicated manufacturing processes for fuel cells have held back the adoption of hydrogen as a fuel. Hydrogen has also been used as a fuel in internal combustion engines. However, these systems may be complex and there are challenges with the safe handling of such systems. Catalytic combustion systems have been used, but such systems often require complex or costly systems to initiate a self-sustaining reaction, such as preheating systems. Even when self-sustaining reactions are started, these systems are often limited by temperatures that can be used due to ablation of catalytic material and concerns regarding the ignition of bulk fuel. There is a need for improved systems and methods for utilizing clean sources of energy. SUMMARY In an aspect, there is provided a catalyst composition including a hydrogen oxidation catalyst (HOC); and an oxygen reduction catalyst (ORC). The catalyst is adapted for low temperature activation of a hydrogen combustion reaction. In some embodiments the ratio of the surface area of the HOC to surface area of the ORC is between about 9:1 and about 4:1. In some embodiments the ratio of the surface area of the HOC to the surface area of the ORC is about 20:3. In some embodiments the HOC and the ORC are formed by electrodeposition. In some embodiments the catalyst is adapted to activate hydrogen combustion at a temperature of below about 140° C. In some embodiments wherein the catalyst is adapted to activate hydrogen combustion at a temperature of below 20° C. In some embodiments the HOC is a noble metal. In some embodiments the HOC is platinum or palladium. In some embodiments the HOC is palladium. In some embodiments the ORC is stannous oxide. In an aspect, there is provided a process for applying a catalyst composition including providing a substrate; applying a catalyst composition to the substrate to form a catalytic surface. The catalyst composition applied includes a hydrogen oxidation catalyst (HOC) and an oxygen reduction catalyst (ORC). The catalytic surface is adapted for low temperature activation of a hydrogen combustion reaction. In some embodiments the catalytic surface includes an HOC area and an ORC area having a ratio of between about 9:1 and about 4:1. In some embodiments the ratio of the HOC area to the ORC area is about 20:3. In some embodiments the applying of the catalyst composition comprises applying of the HOC and applying of the ORC. In some embodiments ORC is applied after applying of the HOC. In some embodiments the applying of the catalyst composition includes electroplating the HOC, the ORC, or both to the substrate. In some embodiments applying of the catalyst composition includes electroplating the HOC to the substrate. In some embodiments applying of the catalyst composition includes electroplating the ORC to the HOC-applied substrate. In some embodiments applying a precursor to the substrate prior to appl