Significant catalyst savings and reaction kinetics enhancement for catalytic micro-combustors via non-uniform catalyst segmentation

A recent prioritization of energy-efficient and sustainable technologies has fueled an ongoing demand for improving the heat sources necessary to drive thermally dependent processes in portable and small-scale devices. Previous efforts have explored hydrocarbon-based catalytic combustion (and its kinetics and fuel usage efficiency) for reliable heating in microscale devices (TPVs, TEGs, etc.). However, for mesoscale systems that require a larger length scale combustor, fuel management and the ability to maintain consistent heat flux across the combustor become challenging due to kinetics and mass diffusion limitations, which are extrinsic to microscale combustors. In this work, we present the design and experimental evaluation of a compact parallel plate catalytic micro-combustor with non-uniform, segmented catalytic zones that allow for direct control of heating, spatially. Specifically, we performed a comparative FEM study of various catalyst segmentation patterns to further optimize catalyst bed spacing for decreased fuel consumption and improved combustion reaction kinetics. Due to these enhancements, the proposed patterning scheme can achieve similar temperature profiles to those of a fullycoated surface while using 77.8% less catalyst and reducing extreme thermal gradients during the early transient combustion phase. Finally, we demonstrated the capabilities of the proposed catalytic combustor by testing the combustor in a controlled environment.