Catalytic decomposition reactors
A catalyst bed includes a structure defining a plurality of channels configured to receive flow of fluid to be chemically catalyzed. The plurality of channels are oriented at least partially non-parallel to an overall flow direction of the flow from inputs of the plurality of channels to outputs of the plurality of channels. A catalyst is exposed at an exterior of the structure.
1 . A catalyst bed comprising:
a monolithic support defining a plurality of channels configured to receive flow of fluid to be chemically catalyzed, wherein the plurality of channels are oriented at least partially non-parallel to an overall flow direction of the flow from inputs of the plurality of channels to outputs of the plurality of channels,
wherein a catalyst coats the monolithic support and is exposed at an exterior of the monolithic support, and
wherein a composition of the monolithic support is different at different portions of the monolithic support.
2 . The catalyst bed of claim 1 , wherein the monolithic support comprises a first section composed of a first material and a second section composed of a second material different from the first material,
wherein the first section adjoins the second section.
3 . The catalyst bed of claim 1 , wherein the composition of the monolithic support is graded.
4 . The catalyst bed of claim 1 , wherein a composition of the catalyst is different at different portions of the catalyst bed.
5 . The catalyst bed of claim 1 , wherein the plurality of channels twist circumferentially with respect to the overall flow direction.
6 . The catalyst bed of claim 5 , wherein the plurality of channels are arranged annularly around a port extending through the monolithic support.
7 . The catalyst bed of claim 1 , wherein the monolithic support has an open cell shape in which gaps are oriented both axially along the overall flow direction and radially transverse to the overall flow direction.
8 . The catalyst bed of claim 1 , wherein cross-sections along a length of the monolithic support include progressively-rotated versions of a template cross-section.
9 . The catalyst bed of claim 1 , wherein the plurality of channels have a plurality of first ports arrayed at a first plane and a plurality of second ports arrayed at a second plane, and
wherein a density of the first ports at the first plane is different from a density of the second ports at the second plane.
10 . The catalyst bed of claim 9 , wherein the plurality of channels fan out from the plurality of first ports to the plurality of second ports.
11 . The catalyst bed of claim 1 , wherein the monolithic support is formed by additive manufacturing.
12 . The catalyst bed of claim 1 , wherein the monolithic support comprises a first portion composed of a first material and a second portion composed of a second material, wherein the first material has a lower high-temperature limit than the second material.
13 . The catalyst bed of claim 1 , wherein different portions of the monolithic support differ in at least one of wall thickness or channel width.
14 . The catalyst bed of claim 1 , wherein a density of the plurality of channels is different at different cross-sections of the monolithic support in planes perpendicular to the overall flow direction.
15 . The catalyst bed of claim 1 , wherein an extension direction of at least one of the plurality of channels is different at different portions of the monolithic support.
16 . The catalyst bed of claim 1 , wherein the monolithic support comprises repeating unit cells forming a lattice, and wherein a type of lattice formed by the repeating unit cells is different at different portions of the monolithic support.
17 . The catalyst bed of claim 1 , wherein the monolithic support has a stochastic lattice geometry.
18 . The catalyst bed of claim 1 , wherein the monolithic support has a triply periodic minimal surface geometry.
19 . The catalyst bed of claim 1 , wherein the monolithic support comprises at least one of a refractory metal or a ceramic.
20 . A catalyst bed comprising:
a structure defining a plurality of channels configured to receive flow of fluid to be chemically catalyzed, wherein the plurality of channels are oriented at least partially non-parallel to an overall flow direction of the flow from inputs of the plurality of channels to outputs of the plurality of channels, and
wherein a catalyst is exposed at an exterior of the structure,
wherein the plurality of channels have a plurality of first ports arrayed at a first plane and a plurality of second ports arrayed at a second plane, the plurality of first ports being connected to respective ones of the plurality of second ports by respective ones of the plurality of channels, such that a number of the plurality of first ports matches a number of the plurality of second ports, and
wherein a number density of the plurality of first ports at the first plane is different from a number density of the plurality of second ports at the second plane.
21 . The catalyst bed of claim 20 , wherein the plurality of channels fan out from the plurality of first ports to the plurality of second ports.
22 . The catalyst bed of claim 20 , wherein the structure comprises a monolithic support, and wherein the monolithic support has a dome shape.
23 . The catalyst bed of claim 20 , wherein the structure comprises a monolithic support,
wherein the plurality of first ports are entrance ports of the monolithic support, and
wherein the plurality of second ports are exit ports of the monolithic support.
24 . The catalyst bed of claim 20 , wherein a first channel of the plurality of channels comprises:
a first section extending away from a central axis of the structure along the overall flow direction, and
a second section extending toward the central axis of the structure.
25 . The catalyst bed of claim 24 , wherein the first section is between an entrance port of the first channel and the second section.