Composite catalyst bed and method for making the same

Power plants – Reaction motor – Method of operation

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23288R, 23288F, 60299, 60300, 60303, 181 71, 252477R, 252477Q, 60 3982C, C06D 504, B01J 800, B01J 3504

Patent

active

040274764

ABSTRACT:
A composite catalyst bed comprising a foam metal matrix packed with a plurality of catalyst particles. The foam metal matrix is a three dimensional, structurally rigid network of interconnected ligaments which define a plurality of interconnected pores filled by particles of a suitable catalyst, such as Shell 405. The composite structure is made by first filling the foam metal matrix with the catalyst particles and then compressing the same so that the catalyst particles become packed tightly in the matrix, with some of the catalyst particles being formed into the ligaments of the matrix. The composite catalyst bed is shown in a monopropellant reactor to decompose hydrazine based monopropellants, and also in a catalytic muffler to oxidize exhaust combustion products from an internal combustion engine. The foam metal matrix retains the catalyst particles in place to alleviate attrition of the particles, and also provides good thermal conductivity to improve performance of the catalyst.

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