Microscale combustor-heat exchanger

Abstract

A miniaturized power generation device and method are provided. In one configuration a microscale combustor and heat exchanger may include several repeating unit cells each of which performs combustion, recuperation, and heat exchange. Catalytic combustion may occur inside at least one combustion and one recuperator channel. Specific features may be added to reduce heat loss and pressure drop.

What is claimed is: 
     
         1 . A microscale combustor and heat exchanger, comprising:
 a plurality of layers each comprising one or more respective channels extending therethrough, the layers joined to one another to permit gaseous communication between selected respective channels of the layers, the plurality of layers comprising:
 a combustor layer comprising at least one combustion channel having a catalyst disposed therein; and 
 a recuperator layer comprising at least one recuperation channel having a catalyst disposed therein, the at least one recuperation channel disposed in gaseous communication with a respective one of the at least one combustion channel to receive a combustion gas therefrom. 
   
     
     
         2 . The microscale combustor and heat exchanger according to  claim 1 , wherein the combustor layer and recuperator layer are disposed in stacked arrangement so that the at least one recuperation channel and the at least one combustion channel are disposed over one another with a common channel wall therebetween. 
     
     
         3 . The microscale combustor and heat exchanger according to  claim 2 , wherein the at least one recuperation channel and at least one combustion channel are oriented relative to one another such that the catalyst containing portion of the at least one recuperation channel is adjacent the catalyst containing portion of the at least one combustion channel. 
     
     
         4 . The microscale combustor and heat exchanger according to  claim 1 , comprising an additional recuperator layer comprising at least one recuperation channel disposed therein disposed in gaseous communication with a respective one of the at least one combustion channel to receive a combustion gas therefrom. 
     
     
         5 . The microscale combustor and heat exchanger according to  claim 4 , wherein the at least one recuperation channel of the additional recuperator layer has a catalyst disposed therein. 
     
     
         6 . The microscale combustor and heat exchanger according to  claim 1 , wherein one or more of the at least one recuperation channel and at least one combustion channel comprises pin fins disposed therein. 
     
     
         7 . The microscale combustor and heat exchanger according to  claim 1 , wherein the plurality of layers includes a heat exchange layer comprising at least one heat exchange channel disposed therein and wherein the recuperator layer is disposed between the heat exchange layer and the combustor layer. 
     
     
         8 . The microscale combustor and heat exchanger according to  claim 1 , wherein one or more of the plurality of layers comprises a shroud disposed between the one or more respective channels and an edge of the layer. 
     
     
         9 . The microscale combustor and heat exchanger according to  claim 8 , wherein the shroud includes a passageway extending through the layer in which the shroud is disposed. 
     
     
         10 . The microscale combustor and heat exchanger according to  claim 8 , wherein one or more of the plurality of layers comprises a groove disposed therein between the shroud and an edge of the layer. 
     
     
         11 . The microscale combustor and heat exchanger according to  claim 1 , wherein one or more of the plurality of layers comprises a groove disposed therein between the one or more respective channels and an edge of the respective layer. 
     
     
         12 . The microscale combustor and heat exchanger according to  claim 1 , wherein ratio of the area of catalyst in the combustion channel to the area of catalyst in recuperation channel is the range of 1/10 to 9/10. 
     
     
         13 . The microscale combustor and heat exchanger according to  claim 1 , wherein ratio of the amount of catalyst in the combustion channel to the amount of catalyst in recuperation channel is the range of 1/10 to 9/10. 
     
     
         14 . A microscale combustor and heat exchanger, comprising:
 a plurality of layers each comprising one or more respective channels extending therethrough, the plurality of layers comprising a combustor layer having at least one combustion channel disposed therein, and a heat exchange layer having at least one heat exchange channel disposed therein; and   a casing disposed around and enclosing the plurality of layers and comprising an inner wall defining a cavity disposed therein, the cavity dimensioned to provide a gap between at least a portion of the inner wall and the plurality of layers, wherein the at least one heat exchange channel is disposed in gaseous communication with the gap.   
     
     
         15 . The microscale combustor and heat exchanger according to  claim 14 , wherein the plurality of layers includes a recuperator layer comprising at least one recuperation channel disposed therein, and wherein the recuperator layer is disposed between the heat exchange layer and the combustor layer. 
     
     
         16 . The microscale combustor and heat exchanger according to  claim 15 , wherein the combustor layer and the recuperator layer are disposed in stacked arrangement so that the at least one recuperation channel and at least one combustion channel are disposed over one another with a common channel wall therebetween. 
     
     
         17 . The microscale combustor and heat exchanger according to  claim 15 , wherein one or more of the at least one combustion channel, at least one recuperation channel, and at least one heat exchange channel comprises pin fins disposed therein. 
     
     
         18 . The microscale combustor and heat exchanger according to  claim 15 , wherein the at least one recuperation channel has a catalyst disposed therein. 
     
     
         19 . The microscale combustor and heat exchanger according to  claim 14 , wherein the at least one heat exchange channel includes an inlet in gaseous communication with the gap and wherein the recuperator and combustor layers each include respective working fluid outlet ports in gaseous communication with the gap. 
     
     
         20 . The microscale combustor and heat exchanger according to  claim 19 , wherein the inlet of the heat exchange channel is disposed at an edge of the heat exchange layer. 
     
     
         21 . The microscale combustor and heat exchanger according to  claim 14 , wherein one or more of the plurality of layers comprises a groove disposed therein between the one or more respective channels and an edge of the respective layer. 
     
     
         22 . The microscale combustor and heat exchanger according to  claim 21 , wherein the groove comprises a through hole extending through the layer in which the groove is disposed. 
     
     
         23 . The microscale combustor and heat exchanger according to  claim 14 , wherein one or more of the plurality of layers comprises two concentric grooves disposed therein, the grooves disposed between the one or more respective channels and an edge of the respective layer. 
     
     
         24 . The microscale combustor and heat exchanger according to  claim 14 , wherein the at least one combustion channel has a catalyst disposed therein. 
     
     
         25 . The microscale combustor and heat exchanger according to  claim 14 , wherein at least one of the plurality of layers comprises an upper surface and a lower surface each of which surfaces includes a respective channel disposed therein. 
     
     
         26 . A microscale heat exchanger, comprising:
 a plurality layers each comprising one or more respective channels extending therethrough, the plurality of layers comprising one or more heat exchange layers having at least one heat exchange channel disposed therein, the plurality of layers disposed in stacked arrangement so that at least one channel from each of two or more layers is disposed adjacent one another with a common wall therebetween through which heat may be exchanged,   wherein the plurality of layers comprises a shroud disposed between the one or more respective channels and associated respective edges of the layers.   
     
     
         27 . The microscale heat exchanger according to  claim 26 , wherein the plurality of layers includes a combustor layer comprising at least one combustion channel. 
     
     
         28 . The microscale heat exchanger according to  claim 26 , wherein one or more of the plurality of layers comprises a groove disposed therein between the shroud and an edge of the layer. 
     
     
         29 . The microscale heat exchanger according to  claim 26 , wherein the shroud includes a passageway extending through the layer in which the shroud is disposed. 
     
     
         30 . The microscale heat exchanger according to  claim 26 , wherein one or more of the plurality of layers comprises a groove disposed therein between the shroud and an edge of the layer. 
     
     
         31 . The microscale heat exchanger according to  claim 30 , wherein the groove comprises a through hole extending through the layer in which the groove is disposed. 
     
     
         32 . A microscale combustor, comprising:
 a plurality of layers each comprising one or more respective channels extending therethrough, the layers joined to one another to permit gaseous communication between selected respective channels of the layers, the plurality of layers comprising a combustor layer comprising at least one combustion channel having a catalyst disposed therein; and
 an electric heater disposed in thermal communication with the at least one combustion channel.