Electrical coupling for resistive heated reactor system

Abstract

An electrical coupler for a resistance heated reactor system includes an electrical conductor having a first end and a second end, defining a thickness between the first end and the second end, the first end and the second end having a first interface in the first end and a second interface in the second end, respectively, and at least one opening extending from the first end to the second end, the at least one opening configured to allow fluid flow through the electrical coupler.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 524,468, filed June 30, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0002] This invention relates generally to the field of resistance heating, and more specifically to new and useful electrical couplers (e.g., electrodes) and / or methods of use in the field of resistance heating. background

[0003] Traditional catalytic reactor systems are heated via external combustion of fuel. The heat from combustion is transferred through the reactor walls to the process flow via radiation and conduction to drive the reactions within the system. This allows the heat-generating mechanism to be separated from the catalytic surface and process gases, but results in poor heat utilization and the generation of significant amounts of CO2 during combustion. The heat transfer efficiency of these systems is typically 50% or lower. Therefore, a more efficient and economical method for heating reactor systems is needed. Brief description of the attached diagram

[0004] The accompanying drawings, which are briefly described below, provide a detailed description of various aspects, features, and embodiments of the subject matter described herein. The drawings are illustrative and not necessarily drawn to scale; some parts and features are enlarged for clarity. The drawings illustrate various aspects and features of the subject matter of the invention and may depict one or more embodiments or examples of the subject matter of the invention, either wholly or in part.

[0005] Figure 1 These are perspective and plan views of schematic diagrams of an example of an electrical coupler.

[0006] Figures 2A-2D This is a schematic diagram of various implementation schemes of an electrical coupler used in a reactor system with resistance heating.

[0007] Figure 3A This is a schematic diagram of an exemplary reactor utilizing an electrical coupler.

[0008] Figure 3B This is a schematic diagram illustrating an example of mechanical interlocking between an electrical coupler and a catalytic element.

[0009] Figure 3C This is a schematic diagram of an exemplary interface between an electrical coupler and a catalytic element.

[0010] Figures 3D-3F This is a schematic diagram of an exemplary electrical coupler and catalytic element interface.

[0011] Figures 4A-4G This is a representation of several exemplary contact types of an electrical coupler.

[0012] Figures 5A-5E These are several views (e.g., cross-sectional perspective view, isometric view, etc.) of an exemplary interface 500 for an electrical coupler.

[0013] Figure 6 This is a schematic diagram of an electrical coupler used in a reactor system with resistance heating.

[0014] Figure 7 This is an example of a radial coupler used in a reactor system with resistance heating.

[0015] Figure 8 This is a schematic diagram of an example of a reactive component of a resistance-heated reactor.

[0016] Figures 9A-9F This is a schematic diagram of an example of a reactive component of a reactor used for resistance heating, showing an exemplary fluid flow path.

[0017] Figure 10 This is a schematic diagram of an example of a catalytic element integrated into a reactor.

[0018] Figure 11 This is a schematic diagram of an example of an exemplary catalytic element having an electrical connection spanning the width (e.g., diameter) of the catalytic element. Detailed Explanation

[0019] The following description of embodiments of the present invention is not intended to limit the invention to these embodiments, but rather to enable those skilled in the art to make and use the invention.

[0020] 1. Overview like Figure 8 As shown, the system preferably includes an electrode pair (e.g., an anode and cathode, an electrocoupler) and a catalytic element. The electrode pair and catalytic element are preferably configured to allow fluid (e.g., gas, liquid) to flow through them. In a preferred embodiment, the electrode pair is configured such that the pressure drop across the fluid is smaller than the pressure drop across the catalytic element.

[0021] Specific examples of the system may include an electrical coupler (e.g., a reactor system for resistance heating), the electrical coupler including an electrical conductor and at least one opening, the electrical conductor having a first end and a second end, a thickness defined between the first end and the second end, the first end and the second end having a first interface in the first end and a second interface in the second end, respectively, and the at least one opening extending from the first end to the second end, the at least one opening being configured to allow fluid to flow through the electrical coupler.

[0022] In another specific example of the system, the system (e.g., a reactor, a resistance-heated reactor, etc.) may include: a pressure vessel having a first vessel end and a second vessel end, wherein a sidewall is external to each of the first and second vessel ends and extends between the first and second vessel ends; a first electrical coupler disposed at the first vessel end and coupled to a first circular end of the pressure vessel, the first electrical coupler having a first electrical conductor and at least one opening, the first electrical conductor having a first end and a second end, a thickness defining the first end and the second end, the at least one opening extending from the first end to the second end, the at least one opening being configured to allow fluid to flow through it into the pressure vessel; a second electrical coupler disposed at the second vessel end and coupled to the second vessel end of the pressure vessel, the second electrical coupler having a second electrical conductor and at least one opening, the second electrical conductor having a third end and a fourth end, a thickness defining the third end and the fourth end, the at least one opening extending from the third end to the fourth end, the at least one opening being configured to allow fluid to flow from the pressure vessel through the second electrical coupler; and a catalytic element disposed within the pressure vessel, the catalytic element being in contact with the first and second electrical couplers.

[0023] In a third specific example of the system, the resistance-heated reactor may include: a proximal end (e.g., having a planar porous fluid inlet); at least one catalytic element having a first end and a second end, wherein a sidewall extends between the first end and the second end; a first electrical coupler having a first end and a second end, an electrical coupler sidewall defined between the first end and the second end, the electrical coupler sidewall being configured to externally connect a first portion of the sidewall of at least one catalytic element; a second electrical coupler having a first end and a second end, an electrical coupler sidewall defined between the first end and the second end, the electrical coupler sidewall being configured to externally connect a second portion of the sidewall of at least one catalytic element, the second electrical coupler being laterally spaced from the first electrical coupler; a first partition disposed between the first electrical coupler and the second electrical coupler externally connecting at least one catalytic element; a second partition disposed between the first electrical coupler and the second electrical coupler externally connecting at least one catalytic element, the second partition being spaced apart from the first partition; and a distal end having a planar porous fluid outlet. In variations of the third specific example (e.g., ... Figure 11 As shown), the electric coupler connection can span the diameter or width of the catalytic element (for example, the first electric coupler can be surrounded, enclosed, or sealed within the catalytic element, and the catalytic element can be surrounded, enclosed, or sealed by the second electric coupler).

[0024] In some variations of the first, second, or third illustrative examples above, the positive and negative couplers of a single component (coupler-catalyst element-coupler assembly) can be connected in parallel, in series, or in combination within a single pressure vessel (e.g., to achieve a multi-unit arrangement). These multi-unit arrangements can be beneficial for regulating the voltage and / or current requirements of the reactor system.

[0025] However, other suitable reactor configurations, catalytic elements, and / or electrical couplers can be used.

[0026] 2. Technological Advantages Variations of this technology can provide one or more advantages over conventional technologies.

[0027] Thermal reactor systems typically operate at high temperatures (e.g., exceeding 1000°C) and high pressures (e.g., exceeding 1 bar) in the presence of corrosive gases (e.g., in the presence of one or more of carbon monoxide, hydrogen, oxygen, ozone, ammonia, carbon dioxide, sulfur oxides, nitrogen oxides, fluorine, chlorine, bromine, iodine, hydrogen sulfide, ethylene oxide, carbonyl sulfide, methanethiol, ethanethiol, propanethiol, butanethiol, hydrogen cyanide, silane, phosphine, etc.). Therefore, variations of the invention can include designs for electrical couplers (e.g., contactors, electrodes, etc.) that can supply electrical energy or current to the catalyst without significantly affecting reactor performance (e.g., without shortening reactor life). For example, structured electrical contacts can be designed to have low resistivity relative to the catalyst (e.g., catalytic element), be fluid permeable to fluid flow, and be stable against degradation (e.g., caused by corrosive gas environments, increased pressure, increased temperature, etc.).

[0028] Second, variations of the electrical coupler may include features that allow them to be used as structural components, electrical interfaces, pressure vessel components and / or compliant sub-components (and others), thereby reducing the complexity of reactor design and / or the number of components.

[0029] Third, variations of this technology can be designed to mitigate the risk of electrode damage. In variations involving straight catalytic members, where the fluid flows substantially parallel to the long axis of the catalytic member, the downstream electrode is frequently exposed to the most reactive conditions (e.g., for example...). Figure 9A (as shown), and therefore may be prone to degradation. To overcome this problem, the catalytic member can be designed such that two (or all when more than two electrodes are used) electrodes are upstream of the catalytic member relative to the fluid flow. For example, the catalytic member can have a chevron (e.g., V-shape), U-shape, convex, arched, plow-shaped, zigzag, serpentine, or other similar shape, wherein the ends of the catalytic member are on a common side (e.g., where the wide face of the electrode is substantially normally connected to the catalytic member, such as...). Figure 9D (As shown). In other instances, the second electrode may be arranged orthogonally to the first electrode, where fluid substantially does not flow over the second electrode.

[0030] However, additional advantages can be provided by the systems and methods disclosed herein.

[0031] 3. Thermal reactor Thermal reactors are preferably used for carrying out (e.g., promoting, enabling, initiating, sustaining, etc.) reactions between two or more chemical substances. The chemical substances are typically in a fluid phase (e.g., gas, liquid, plasma, etc.). However, one or more chemical substances can be in a solid phase and / or other suitable material phase. For example, a thermal reactor can be used for carrying out a reverse water-gas shift reaction (e.g., Alternatively, a thermal reactor can be used for steam-based methane reforming. ), dry methane reforming ( ), Haber process ( ), Kværner process ( ) and / or other suitable industrial processes (especially using gaseous reactants and ideal gaseous products, endothermic reactions, etc.).

[0032] Thermal reactors are typically operated at standard pressures or higher (e.g., between 1 atm and 100 atm). However (e.g., to control product ratios, control by-product recovery rates, etc.), thermal reactors can be operated under reduced pressures (e.g., vacuum, pressures less than 1 atm, etc.).

[0033] For example Figure 8 As shown, a thermal reactor may include reaction modules (e.g., electrical couplers or electrodes and catalytic elements). The thermal reactor may optionally include one or more of a pressure vessel, interface, compression element, inlet and / or outlet (e.g., reagent port and / or product port) and / or other suitable elements.

[0034] In some variations, the thermal reactor may include more than one reaction module. The more than one reaction module may be arranged in parallel (e.g., fluid flows through the reaction module simultaneously, concurrently, or concurrently), in series (e.g., fluid flows from one reaction module to a subsequent reaction module), and / or in any suitable combination thereof (e.g., more than one parallel reaction module, wherein one or more of the more than one includes more than one reaction module in series, branched reaction modules, etc.).

[0035] The reaction module is preferably used as the site for carrying out chemical reactions. The reaction module (e.g., its catalytic element) preferably achieves high operating temperatures (e.g., greater than about 500°C, 600°C, 750°C, 800°C, 900°C, 1000°C, 1100°C, 1250°C, 1300°C, 1500°C, 2000°C, 2500°C, etc.), which can advantageously drive the equilibrium of the chemical reaction towards the preferred product. However, a thermal reactor can be operated in any suitable manner.

[0036] The reactor temperature is preferably achieved via resistance heating (e.g., Joule heating, ohmic heating, etc.). However, the reactor temperature can be achieved in other ways (e.g., dielectric heating, induction heating, etc., for suitable catalyst elements, reaction modules, etc.).

[0037] The energy to achieve the reactor temperature is preferably provided via renewable energy sources (e.g., in the form of electricity). When Joule heating (resistive heating) is used to power the system, it is preferable that the heat generation is closely coupled to the catalyst material to maximize heat transfer to the catalytic sites. This form is characterized by including an electrical feedthrough that penetrates the reactor wall and provides a large amount of electricity to the catalytic elements housed within the reactor.

[0038] An electrical coupler (e.g., an electrode) is preferably used to supply power (e.g., current, electrical energy, etc.) to the catalytic module. The electrical coupler preferably has a lower resistance than the catalytic module (e.g., so that resistance heating occurs in the catalytic module rather than at the electrical coupler).

[0039] Typically, two electrical couplers are used for each catalytic module (e.g., one as an anode and one as a cathode). However, a greater number of electrical couplers can be used (e.g., more than one anode and / or cathode), which can be beneficial in improving the heating uniformity of the catalytic element (e.g., by improving the uniformity of current, potential drop, etc., through the catalytic element). In some variations, a single electrical coupler can be used (e.g., where the electrical coupler is designed to have both an anodic and a cathodic action region, and the catalytic element is designed to allow current to flow through the entire catalytic element rather than short-circuiting in the region of the catalytic element near the electrical coupler).

[0040] In some variations, the electrical coupler can be designed to allow fluid flow through the electrical coupler (e.g., as shown in example...). Figure 9A , Figure 9C , Figure 9E , Figure 9F(As shown). In these variations, the electrocoupler preferably has a smaller pressure drop than the catalytic element (e.g., the electrocoupler has less resistance to fluid flow). In addition to or as a substitute for pressure drop, the electrocoupler can be additionally or alternatively designed to achieve uniform electrical properties (e.g., current, potential drop, etc.) within the catalytic element (typically achieved by having greater coverage or contact between the catalytic element and the electrocoupler) through a target current (e.g., 0.005 A, 0.01 A, 0.05 A, 0.1 A, 0.5 A, 1 A, 1.5 A, 2 A, 5 A, 10 A, 15 A, 20 A, 50 A, 500 A, 5000 A, etc.) to mitigate the risk of reactions or degradation occurring on the electrocoupler (e.g., typically achieved by having a smaller exposed surface area), and / or can be designed in other ways. The benefits of these variations may include the use of an electrical coupler to mix or improve the mixing of fluids before they enter the catalytic element, to increase the residence time of fluids within the catalytic element, and / or to provide other suitable benefits.

[0041] Examples of electrical coupler structures that can be used to enable fluid flow include drilled or through holes in the electrical coupler, mesh electrical couplers, fiber-reinforced electrical couplers, porous electrical couplers, and / or other such techniques for enabling fluid to pass through the electrical coupler.

[0042] In variations using engineered fluid flow structures (e.g., boreholes, through-holes, etc.), the flow structure for the electrical coupler pair can be aligned (e.g., such that fluid can flow along a straight or linear path between openings when there are no objects between the electrical couplers), antialigned (e.g., such that fluid can not flow along a straight or linear path between openings when there are no objects between the electrical couplers), random or partially aligned (e.g. such that fluid can flow along a straight or linear path between or a portion of the openings when there are no objects between the electrical couplers), and / or can have any suitable alignment.

[0043] Typically, electrocouplers are arranged such that the surface normal of the wide face of the electrocoupler is parallel to the direction of fluid flow (e.g., for example...). Figure 9A , Figure 9E or Figure 9F (As shown). However, the electrical coupler can be arranged such that the surface normal of the wide face of the electrical coupler is perpendicular to the direction of fluid flow (e.g., for example). Figure 9B , Figure 9D or Figure 10 (as shown) and / or intersect the direction of fluid flow at any angle (e.g., as shown) Figure 9C (As shown).

[0044] In some variations (e.g., for example) Figure 9EAs shown), the reaction module can be designed such that the electrocoupler is positioned upstream of the catalytic element within the fluid flow. These variations can be achieved, for example, by using U-shaped (e.g., horseshoe-shaped, keyhole-shaped, ω-shaped, crescent-shaped, lecotropal, etc.), V-shaped (e.g., herringbone), plow-shaped, zigzag, sinusoidal, snake-shaped, bow-shaped, and / or other suitable shaped catalytic elements, wherein the ends of the catalytic element are on the same side (e.g., the surfaces perpendicular to each end are parallel). These variations can provide the technical advantage of keeping the electrocoupler in a lower temperature region within the fluid flow (thus reducing electrocoupler degradation). Alternatively or additionally, the reaction module can be designed such that a single electrocoupler in the fluid path (e.g., the surfaces perpendicular to each end of the catalytic element are perpendicular), wherein the single electrocoupler in the fluid path is preferably upstream of the catalytic element. However, the electrocoupler can be positioned downstream of the catalytic element in the fluid flow (e.g., as shown). Figure 9F (as shown) and / or one electrical coupler can be arranged upstream of the catalyst element and the other electrical coupler can be arranged downstream of the catalyst element (e.g., as shown) Figure 9A or Figure 9C (As shown).

[0045] The electrocoupler is preferably designed to allow large volumes of fluid, such as gas or liquid, to flow through the electrocoupler (contactor) and be guided through the catalytic element. The fluid flow path exiting the electrocoupler preferably does not adversely affect the interaction between the gas phase and the catalytic element. The electrocoupler preferably distributes the fluid flow uniformly across the cross-section of the catalytic element. The gas path of the electrocoupler can be a single opening (e.g., a hole or gap with a diameter of 0.5 cm to 10 cm), more than one smaller opening (0.01 cm to 5 cm in diameter), a tortuous path (e.g., porous, channeled, gaps between fibers, etc.), and / or can be designed in other ways. In variations using these, more than one smaller opening can allow for an increased flow distribution across the catalytic element and provide a more dispersed contact for the current from the electrocoupler to the catalytic element (which can be beneficial for uniform heating of the catalytic element). The voltage drop across the electric coupler should be smaller than the voltage drop across the catalytic element (e.g., resistive element) (e.g., <50%, <30%, <25%, <20%, <10%, <5%, <1%, etc.).

[0046] However, an electrical coupler can be designed such that fluid can pass through only a portion of the electrical coupler (or a portion of the surface in contact with the electrical coupler) (e.g., for example...). Figure 9D (as shown) and / or the fluid cannot pass through the electrical coupler (e.g., as shown) Figure 9B(As shown). These variations can help reduce the risk of damage to the electrical coupler caused by passing heated fluid through it.

[0047] Electrical couplers are preferably formed of conductive material. Electrical couplers may be formed wholly or partially of conductive material. In some variations, electrical couplers may have insulating material applied thereto, such as decals or components fastened thereto.

[0048] The electrical coupler is preferably made of refractory materials (e.g., semiconductor, conductive, and other refractory materials), metals (e.g., refractory metals), and / or combinations thereof (e.g., cermet materials). Preferred examples of electrical coupler materials include: carbon (e.g., graphite electrodes), silicon carbide (e.g., silicon-silicon carbide, carbon-silicon carbide), tungsten carbide, molybdenum carbide, titanium carbide, vanadium carbide, chromium carbide, zirconium carbide, niobium carbide, molybdenum carbide, ruthenium carbide, rhodium carbide, hafnium carbide, tantalum carbide, tungsten carbide, rhenium silicide, osmium silicide, iridium carbide, platinum silicide, titanium silicide, vanadium silicide, chromium silicide, zirconium silicide, niobium silicide, molybdenum silicide, ruthenium silicide, rhodium silicide, hafnium silicide, tantalum silicide, tungsten silicide, rhenium silicide, osmium silicide, iridium silicide, neptunium silicide, titanium, vanadium, chromium, zirconium, niobium, molybdenum, ruthenium, rhodium, hafnium, tantalum, tungsten, rhenium, osmium, iridium, alloys or composites thereof, and / or other similar materials. In some variations, the electrical coupler material may include dopants (e.g., metal dopants, p-type dopants, n-type dopants, etc.) to increase the conductivity of the electrical coupler.

[0049] An electrical coupler can be formed from a single continuous component, for example, as a continuous block of metal that is machined, molded, cast, or otherwise shaped to have the geometry described herein. In various embodiments, the electrical coupler can be formed from a single continuous component made of any material as described herein. The electrical coupler can be configured to conduct electrical power from one or more power interfaces due to the geometry and material of the device, and to allow fluid to flow through it (e.g., by geometric considerations). Additionally or alternatively, the electrical coupler can be configured to couple to one or more external systems (e.g., inside or outside a reactor system) by the nature of its geometric features, such as interfaces.

[0050] Catalytic elements are used to drive (e.g., increase reaction rate, lower reaction energy barrier, etc.) a target chemical reaction. Catalytic elements are preferably positioned between at least two electrical couplers (e.g., an anode and a cathode). However, a single electrical coupler (acting as both a cathode and an anode) can be used (e.g., when the electrical path through the catalytic element traverses a large portion of the catalytic element's volume before connecting the anode to the cathode).

[0051] Catalytic elements can be cylindrical, prismatic (e.g., pyramidal, prismal, anti-prism, parallelepiped, dome-shaped, truncated, cubic, rectangular prism, triangular prism, pentagonal prism, etc.), toroidal (e.g., square toroidal, rectangular toroidal, hexagonal toroidal, degenerate toroid, etc.), conical, and / or can have other suitable shapes (typically, but not necessarily, 3D shapes with two planar wide surface ends). Typically, the ends are antiparallel (e.g., axes across the catalytic element are opposite each other). However, the ends can be orthogonal, parallel (e.g., U-shaped, V-shaped, herringbone, plowshare-shaped, zigzag, sinusoidal, serpentine, etc., where the ends are in the same plane or otherwise have surface normals pointing in the same direction), and / or can be otherwise related or have suitable structures. In some variations (e.g., ... Figure 9D As shown, the electrocoupler can be configured to be coupled to the catalytic element from the side rather than the end.

[0052] Catalytic elements can be partially formed from conductive or semiconductor materials. In some variations, catalytic elements can be formed entirely from conductive or semiconductor materials. In some variations, catalytic elements can be formed from a conductive material and a catalytic material applied to the conductive material.

[0053] Catalytic elements may include a substrate, a catalyst, and / or any suitable components. In some variations, the substrate may be formed from a catalyst material (e.g., the substrate and catalyst may be the same).

[0054] The substrate is used to support the catalyst and / or heat the catalyst and / or the fluid. The substrate may additionally or alternatively be used to mix the fluid (e.g., by introducing turbulence into the fluid flow), increase the residence time of the fluid near the catalyst (e.g., by forming a tortuous path through the substrate), and / or may function in other ways.

[0055] The substrate is preferably formed of refractory materials, refractory metals, and / or combinations thereof (e.g., cermets). For example, the substrate may be made of the same or different materials that can form the electrical coupler (carbon, silicon carbide, tungsten carbide, molybdenum carbide, titanium carbide, vanadium carbide, chromium carbide, zirconium carbide, niobium carbide, molybdenum carbide, ruthenium carbide, rhodium carbide, hafnium carbide, tantalum carbide, tungsten carbide, rhenium carbide, osmium carbide, iridium carbide, platinum silicide, titanium silicide, vanadium silicide, chromium silicide, zirconium silicide, niobium silicide, molybdenum silicide, ruthenium silicide, rhodium silicide, hafnium silicide, tantalum silicide, tungsten silicide, rhenium silicide, osmium silicide, iridium silicide, neptunium silicide, titanium, vanadium, chromium, zirconium, niobium, molybdenum, ruthenium, rhodium, hafnium, tantalum, tungsten, rhenium, osmium, iridium, alloys or composites thereof, etc.). Other examples of substrate materials include oxides (e.g., titanium dioxide, aluminum oxide, cerium dioxide, zinc oxide, zirconium oxide, silicon dioxide, etc.), nitrides, and / or other suitable materials (e.g., which may include dopants to modify the electrical properties of the substrate to promote uniform thermal and / or electrical distribution throughout the catalytic element).

[0056] The substrate preferably has a high specific surface area (e.g., to promote reaction sites), such as ≥1 m². 2 / g, ≥10 m 2 / g, ≥100 m 2 / g, ≥1000 m 2 / g, and / or other surface areas (e.g., BET surface area). However, the substrate can have any suitable specific surface area.

[0057] The substrate is preferably a porous material (e.g., a material with a porosity greater than 5%, a material with a solid volume of up to 95%, etc.). For example, the substrate can be a foam (e.g., an open-cell foam, a random foam, a regular foam, etc.), a woven fiber, a periodic open-cell structure, a lattice, and / or can have any suitable structure. However, the substrate can additionally or alternatively be a solid material (e.g., a mesh, a tape, etc.), including engineered structures (e.g., a roughened surface to promote a large surface area), and / or can be formed in other ways.

[0058] Catalysts are used to lower the activation energy of a target chemical reaction (e.g., increase the reaction rate, promote reaction centers, etc.). The catalyst is preferably disposed on a substrate (e.g., coated, adhered to, absorbed on, adsorbed on, etc.). Alternatively or additionally, the catalyst may be integrated into the substrate (e.g., where at least a portion of the catalyst material protrudes from the substrate material), may be disposed on an electrical coupler (e.g., to increase the total catalyst loading within the reaction module and / or reactor), and / or may be arranged in other ways.

[0059] Examples of catalyst materials (e.g., for RWGS reactions) may include: oxides (e.g., iron oxide, chromium oxide, copper oxide, aluminum oxide, zinc oxide, cerium oxide, iron oxide, manganese oxide, indium oxide, nickel oxide, spinel oxide, solid solution oxide, perovskite oxide, complexes or combinations thereof, etc.), metal catalysts (e.g., platinum, palladium, gold, rhodium, ruthenium, copper, nickel, rhenium, cobalt, iron, molybdenum, etc.), phosphides (e.g., copper phosphide, nickel phosphide, tungsten phosphide, cobalt phosphide, molybdenum phosphide, combinations thereof, etc.), promoters (e.g., alkali metals, noble metals, bimetals, etc.) and / or other suitable catalyst materials (e.g., for a specific reaction, in combination with a specific substrate material, etc.).

[0060] The catalytic element and the electrocoupler can be mechanically connected (e.g., physically compressed together, such as using springs, pneumatic systems, hydraulic systems, vacuum, motors, Belleville washer, etc.), chemically connected (e.g., using adhesives, such as carbon), and / or using any suitable connection mechanism.

[0061] The electrocoupler is preferably coupled to the catalytic element in a manner that minimizes resistance (e.g., minimizes contact resistance or prevents the formation of a high-resistivity phase) and / or allows for the stable delivery of high current densities to the catalytic element. These coupling properties can provide a technical advantage because high local resistance at the contact or contact interface can create hot spots and / or areas that are easily degraded under reaction conditions. Local resistance can be minimized by using appropriate geometry, material selection, mechanical compression, chemical bonding, and other such processes that ensure tight electrical and physical contact between the electrocoupler and the catalytic element (e.g., without increasing stress such as during thermal expansion and contraction).

[0062] An exemplary method for combining a catalytic element and an electrical coupler includes using an interfacial adhesion layer applied to a ceramic substrate. For example, the adhesion layer is deposited on SiC by placing a foil, thermal spraying, electroplating, or any of chemical vapor deposition (CVD) / physical vapor deposition (PVD) at the interface, while masking the remainder. The adhesion layer can then be activated to combine the catalytic element and the electrical coupler using any of the following: induction heating, resistance heating, laser heating, and ultrasonic vibration.

[0063] Another exemplary method for combining a catalytic element and an electrocoupler includes direct bonding via chemical bonding. For example, diffusion bonding can be utilized. A chemical bond can be induced between two materials by physically placing the components close to each other and applying a force (e.g., exceeding 100 MPa), followed by heating (e.g., up to or above about 2000 °C). Alternatively or additionally, a precursor paste can be used by placing a mixture of Si, C, and a binder at the interface and then heating it to an elevated temperature using any of the heating methods described herein (induction, resistance, radiation, laser, vibration, etc.) to form a chemical bond.

[0064] Another exemplary method of combining a catalytic element and an electrical coupler may include encapsulation via CVD, liquid-phase SiC, and / or other suitable methods (e.g., with SiC).

[0065] Another exemplary method of combining a catalytic element and an electrical coupler may include fabricating the electrical coupler and element in one operation (e.g., using additive manufacturing). Post-processing (e.g., silicon infiltration or other treatments) may then be optionally used (e.g., to further alter the relative conductivity of the coupler and catalytic element).

[0066] Alternatively or alternatively, any component described throughout this disclosure may be mechanically coupled via wet bonding, brazing, diffusion bonding, ultrasonic welding or similar methods.

[0067] 4. Specific examples The methods and systems presented herein can be used for electrical couplers. The disclosed subject matter is particularly suitable for electrical couplers used in reactor systems with resistance heating. For purposes of explanation and illustration, and not limitation, a first specific example of a system based on the disclosed subject matter is provided in... Figure 1 The figures are shown in the figures and are generally designated by reference numeral 100. Similar reference numerals (distinguished by leading numerals) may be used among the various views and figures presented herein to indicate functionally corresponding but not necessarily identical structures. However, reference numerals with different leading numerals may all refer to the same structure (e.g., from different perspectives, different variations of the same structure, etc.).

[0068] The first specific example can be used for an electrical coupler. The disclosed subject matter is particularly suitable for electrical couplers used in reactor systems with resistance heating. For purposes of explanation and illustration, and not limitation, exemplary embodiments of systems based on the disclosed subject matter are described in... Figure 1 The figures are shown and generally designated by reference numeral 100. Similar reference numerals (distinguished by leading numbers) may be used among the various views and figures presented herein to indicate functionally corresponding but not necessarily identical structures.

[0069] Figure 1This is a perspective and plan view of a schematic diagram of a first specific example of an electrical coupler 100 for a reactor system with resistance heating, according to the disclosed subject matter. More than one electrical coupler 100 may be similar or identical in operation, function, and / or physical manner, and thus one or both electrical couplers may be described with reference to electrical coupler 100, or each electrical coupler present in the reactor or reactor system may be described in some figures. Electrical coupler 100 may include a first end 101 and a second end 102, with a thickness 103 defined between the first end 101 and the second end 102. The first end 101 and the second end 102 may be of any cross-sectional shape. For example, but not limited to, the first end and the second end may have a circular cross-sectional shape, thereby forming a cylindrical electrical coupler 100 having two planes with normal circular surfaces as terminals on either side of the thickness 103. In various embodiments, the first end 101 and the second end 102 may have a straight cross-sectional shape, an elliptical cross-sectional shape, or any polygonal cross-sectional shape. The first end 101 and the second end 102 may be parallel to each other, having a normal circular outer wall extending between the first end 101 and the second end 102, forming a right-hand cylindrical electrical coupler 100. For example, but not limited to, the electrical coupler 100 may have a non-parallel first end 101 and second end 102. For example, but not limited to, the first end 101 and the second end 102 may have surface features on their surfaces, such as ridges, ribs, rings, waves, or other protrusions. For example, but not limited to, the cylindrical wall extending between the first end 101 and the second end 102 may be angled, fan-shaped, or include features such as bottlenecks, undulations, corrugations, or the like. In various embodiments, the first end 101 may have a different cross-sectional shape than the second end 102. In various embodiments, the first end 101 may have the same or similar cross-sectional shape as the second end 102, but with different dimensions, thereby forming a tapered or conical cross-sectional shape of the electrical coupler 100.

[0070] A first specific example of the electrical coupler 100 may have an interface 104 within a first end 101. The interface 104 may be formed as one or more countersunk holes having the same planar shape as the end into which it is recessed. For example, a rounded end may have a circular interface 104 disposed therein. The interface 104 may have a countersunk hole bottom with a similar or identical shape to the interface 104; for example, the interface 104 may have a circular bottom. The interface 104 may include internal geometric features such as ridges, ribs, or radial features such as shoulders and necks. The interface 104 may form a first interface having one or more sealing features therein. Similarly, the second end 102 may have a second interface 105, which may be a mirror image of the interface 104. In various embodiments, the countersunk holes of interfaces 104 and 105 have different planar shapes; for example, the first interface 104 may be a circular hole entering the radial center of the first end 101, and the second interface 105 may be a square hole entering the radial center of the second end 102. In various embodiments, each countersunk hole can be drilled to a different depth; for example, the first interface 104 can be deeper than the second interface 105. Interfaces 104 and / or 105 can be interfaces for sealing pressure vessels as described herein. In various embodiments, interfaces 104 and 105 can be formed concentrically in the same end of the electrical coupler 100.

[0071] For example, but not limited to, interfaces 104 and 105 may be radially centered relative to the electrocoupler 100 and have at least one opening 107 therethrough, thereby connecting the first end 101 and the second end 102 or facilitating fluid flow through the first end 101 and the second end 102. In various embodiments, the opening 107 may be radially centered and drilled perpendicular to the electrocoupler 100. At least one opening 107 may be formed at the bottom of each of interfaces 104 and 105. In various embodiments, the opening 107 may be formed during a countersunk hole manufacturing process. In various embodiments, at least one opening 107 is a drilled hole formed perpendicular to the first end 101 and the second end 102, and at least one opening 107 has a diameter of about 0.5 cm to 10 cm.

[0072] In a variation of the first embodiment, at least one opening 107 is formed from the first end to the second end, and each of the openings has a diameter of about 0.01 cm to 1 cm. In another variation of the first embodiment, the openings 107 are formed in a ring concentrically arranged with a normal axis extending from the center of the first end 101 to the center of the second end 102. The mechanical design of the electrical coupler ideally allows for uniform fluid flow through the assembly and may require uniform fluid distribution before it enters the catalytic heating element. When the fluid is not uniformly distributed across the electrical coupler before entering the catalytic element, the efficiency of the element may be significantly reduced. In a variation of the first embodiment, the openings 107 may be formed perpendicular to one or both of the first end 101 and the second end 102. In a variation of the first embodiment, a first portion of the openings 107 may be oriented perpendicular to one or both of the first end 101 and the second end 102, and a second portion of the openings 107 may be formed at an angle to one or both of the first end 101 and the second end 102. In a variation of the first specific example, the electrical coupler 100 may be formed of a structure similar to foam, cork, or sponge, having more than one randomly aligned hole and channel. In a variation of the first specific example, at least one opening 107 is formed in the electrical coupler 100 as more than one channel and / or hole.

[0073] Continue to refer to Figure 1 In a variation of the first specific example, the electrical coupler 100 may have a power interface 108 formed therein. The power interface 108 may be formed or disposed on one of the first ends 101 (as shown) and extend through the second end 102 (as shown). In various embodiments, the power interface 108 may be specifically formed on the surface of the first end 101, the second end 102, or the thickness 103. In a variation of the first specific example, the power interface 108 may be integrally disposed or formed with the electrical coupler 100. In a variation of the first specific example, the power interface 108 may be configured to couple to one or more wires or conduits configured to supply electrical power to the electrical coupler 100. In a variation of the first specific example, voltage drop and heat generation from the electrical connection may be used as a fluid flow preheating system (e.g., using a resistive material as an electrical contact can preheat the fluid flow before it enters a pressure vessel for catalysis).

[0074] Continue to refer to Figure 1In a variation of the first embodiment, the electrical coupler 100 may have a mechanical interface 112. The mechanical interface 112 may be formed or placed on one of the first ends 101 (as shown) and extend through the second end 102 (as shown). In a variation of the first embodiment, the mechanical interface 112 may be specifically formed on the surface of the first end 101, the second end 102, or the thickness 103. In a variation of the first embodiment, the mechanical interface 112 may be placed, machined, drilled, engraved, cut, or integrally formed with the electrical coupler 100.

[0075] In a variation of the first specific example, the mechanical interface 112 may be configured to receive a threaded rod therein. For example, but not limited to, a portion of the mechanical interface 112 may be threaded, allowing the rod to be inserted with partial exposure, such that a nut, washer, pin, or other retaining member can be threaded onto or coupled to the mechanical interface 112. In a variation of the first specific example, the mechanical interface 112 may be configured to press-fit with another component, such as a rod. In a variation of the first specific example, the mechanical interfaces 112 may be radially arranged around the central axis of the electrical coupler 100 at regular intervals. In a variation of the first specific example, the mechanical interfaces 112 may include more than one mechanical interface 112 of the same or different types. For example, but not limited to, the mechanical interface 112 may be one or more slots configured to retain hooks or other bosses, thereby holding any component stationary relative to the electrical coupler 100. For example, but not limited to, the mechanical interface 112 may be adjustable or repositionable. For example, the threaded rod may be rotated to tighten or loosen any two components relative to the electrical coupler 100. For example, mechanical interface 112 can facilitate a seal between two components by tightening via rotation of a threaded rod.

[0076] As a second specific instance (which may be identical to and / or integrated with the first specific instance and its variants with potential design modifications), the electrical coupler 100 is shown in side and plan views (e.g., as shown in Figure 2). Figure 1 and Figures 2A-2D As can be seen, interface 105 can be an interface for one or more fluid supply lines, such as a fluid inlet or fluid outlet. In a variation of the second specific example, interface 105 may include threads or another retaining feature configured to couple and seal a component carrying a fluid (such as gas) to the electrical coupler 100 and supply gas through at least one opening 107. In a variation of the second specific example, the electrical coupler may be fluid-conductive and electrically conductive, and stable in corrosive environments at high temperatures (e.g., ≥500°C, ≥900°C, etc.).

[0077] Continue to refer to Figure 2AIn a variation of the second specific example, the second interface 105 is shown in cross-sectional view and dashed lines. The second interface 104 may form a second interface for the catalytic element (described below) and / or pressure vessel. The second interface (104) may include any number of geometric or material features, such as internal shoulders and rubber gaskets, to form a connection with the electrical coupler 100 (and seal the connection).

[0078] Now for reference Figures 2B-2D Variations of the electrical couplers 100a and 100b of Specific Example 1 or Specific Example 2 are shown in isometric views. In various embodiments, the electrical couplers 100 may be identical at either end of the catalytic element and secured to the catalytic element by the same or similar mechanism. In various embodiments, the electrical coupler 100a may be configured separately from the electrical coupler 100b. For example, but not limited to, the electrical coupler 100a may be configured to be coupled to the catalyst or heater element via a compression-fixing screw connection. However, other suitable fastening mechanisms (e.g., springs) may be used. The electrical coupler 100 may have an opening 107 configured to allow fluid flow through the electrical coupler 100. The opening 107 may be threaded and configured to receive a fixing screw that rotates to compress and form electrical contact with the catalytic element. Additionally or alternatively, the electrical coupler 100b may be configured to have an opening 107 having more than one smaller opening disposed therein. The opening 107 in the electric coupler 100b can be configured to connect external catalytic elements and form a mechanical connection between them.

[0079] In some variations, electrical couplers 100a and / or 100b (e.g., for example) Figure 2C or Figure 2D The (shown) may have an asymmetrical stand-off 204. The stand-off 204 may have a threaded hole formed therein and parallel to the stand-off 204. The (optionally threaded) hole may be configured to form an electrical connection with one or more power interfaces (e.g., wired power connections or the like) described below. In various embodiments, the stand-off 204 may be configured to be electrically coupled to electrical leads in more than one method, such as welding or bolting. The threaded stand-off 204 may be configured to be screwed into a power conductor, which is sealed to the reactor vessel via a feedthrough that isolates the vessel from the surrounding atmosphere. In various embodiments, the electrical couplers 100a, 100b may be configured to be integrated into the catalyst element. The radial symmetry of the countersunk holes and backstops having more than one hole may be configured to match the geometry of any catalyst element.

[0080] As (for example, for example) Figure 3AIn a third specific example of the reactor 300 shown, the reactor may utilize an electrical coupler 100 for a reactor system used for resistance heating. The reactor 300 may include electrical couplers 100 (or substantially similar conductors, electrodes, contactors, etc.) disposed at its distal and proximal ends. The reactor 300 may include a pressure vessel 304. The pressure vessel 304 may have a first circular end and a second circular end, wherein a cylindrical wall is externally circumscribed around the periphery of each circular end and extends between the first and second circular ends to form a cylindrical container. However, the pressure vessel may have a prismatic shape, an annular shape, and / or may use other suitable container structures. The pressure vessel 304 may be disposed within a countersunk hole (105) of each electrical coupler 100a, 100b. The pressure vessel 304 may be sealed against the electrical couplers 100a, 100b (e.g., via one or more O-rings, gaskets, knife-edge seals, etc.). In various embodiments, the pressure vessel 304 may form a press fit with one or both of the electrical couplers 100a, 100b. In various embodiments, pressure vessel 304 may be configured to prevent fluids such as gas or liquid flows 312 from entering or leaving its walls. The pressure vessel may be formed, for example, of quartz crystal and / or other suitable materials capable of withstanding the reaction conditions within the reactor. Pressure vessel 304 may be chemically bonded or adhesively coupled to one or both of electrical couplers 100a and 100b, may be integrally formed with one or both of electrical couplers 100a and 100b, may be mechanically coupled to one or both of electrical couplers 100a and 100b, and / or may be otherwise configured.

[0081] In various embodiments, pressure vessel 304 may have sealing features at a first and a second circular end, which are configured to mate and couple with corresponding features of the first and second electrical couplers 100a, 100b. For example, the edge of pressure vessel 304 may be located within a circular channel formed in a countersunk hole in electrical coupler 100a or 100b. In various embodiments, pressure vessel may be configured to receive fluid flow entering the vessel from an opening in electrical coupler 100a and to guide the fluid flow 312 through second electrical coupler 100b (e.g., via a catalytic element). In various embodiments, H2-stabilized and carburizing-resistant materials may be used to produce weldments and any or all reactor seals.

[0082] In various embodiments, one or both of the first electrical coupler 100a and the second electrical coupler 100b may have a power interface (e.g., as described with reference to the first specific example). In various embodiments, one or both of the first electrical coupler 100a and the second electrical coupler 100b may have a mechanical interface or more than one mechanical interface (e.g., as described in the first or second specific example). In various embodiments, each of the electrical couplers 100a, 100b may have a corresponding mechanical interface, such as a fastener interface, configured to couple the reactor 300 together. For example, at least one threaded rod may be parallel to the cylindrical wall of the pressure vessel 304 and extend from the first electrical coupler 100a to the second electrical coupler 100b outside the cylindrical wall, the threaded rod being configured to compress and couple components of the reactor 300. In various embodiments, the first electrical coupler 100a, the second electrical coupler 100b, and the pressure vessel 304 may be formed as concentric and series-connected cylinders. For example, pressure vessel 304 may have a smaller diameter than the diameter of each of the electrical couplers 100a and 100b. In various embodiments, pressure vessel 304 may have the same diameter as one or both of the electrical couplers 100a and 100b. In other embodiments, pressure vessel 304 may have a larger diameter than the diameter of one or both of the electrical couplers 100a and 100b, wherein the couplers and catalytic elements are housed within the pressure vessel.

[0083] In a third specific example, reactor 300 may include a catalyst element 308. The catalyst element 308 is hermetically disposed (e.g., hermetically sealed, fluid-sealed, etc.) within pressure vessel 304, and is in electrical contact with electrical couplers 100a, 100b. In various embodiments, the catalyst element 308 is in direct electrical contact with each of the electrical couplers 100a, 100b. In various embodiments, the catalyst element is indirectly electrical contact with the electrical couplers 100a, 100b. The catalyst element 308 may be in radial contact (e.g., the electrical coupler 100 may be external to the side of the catalyst element 308 to allow unobstructed fluid flow 312), axial contact (e.g., the electrical coupler 100 may be attached to the end of the catalyst element 308 to allow fluid flow 312 through the coupler and the catalyst element, wherein the fluid flow may occur radially or orthogonally to the electrical coupler, etc.), and / or may otherwise contact the electrical couplers 100a or 100b. In various embodiments, one or more components may optionally be included and configured to facilitate electrical communication between the electrical coupler and the catalytic element, such as compression elements like gaskets, metal foams, and the like. In various embodiments, the electrical couplers 100a, 100b have a coefficient of thermal expansion matching that of the catalytic element 308 and form a low-resistance contact with the catalytic element. The resistance of the electrical coupler is preferably lower than that of the catalytic element 308 (making the catalytic element the primary site of heating), although this is not strictly necessary. As a specific embodiment, the catalytic element may be 3-6 inches wide and 6-12 inches long; however, other suitable materials may be used.

[0084] In a third specific example, reactor 300 may be arranged such that electrical couplers 100a, 100b provide an unobstructed flow of fluid (e.g., gas) 312 through catalytic elements 308 within pressure vessel 304 to provide current to the resistance heating cells and to provide a sealing surface for pressure vessel 304. Reactor 300 may optionally include one or more thermocouples disposed therein, each thermocouple configured to measure temperature in a localized or larger portion of reactor 300. Pressure vessel 304 may be formed of one or more insulating materials configured to improve the thermal efficiency of the system while maintaining optimal fluid flow profile 312. In various embodiments, pressure vessel 304 may be interlocked with one or both of electrical couplers 100a, 100b to form a seal against the fluid flow 312.

[0085] In specific instances (such as, for example) Figure 3BAs shown, a mechanically interlocked connection can be used between an electrical coupler 100 (which may be one or both of electrical couplers 100a and 100b) and a catalytic element 308. The electrical coupler 100 and the catalytic element 308 may have corresponding geometric features, configured to contact to form a mechanically interlocked connection (e.g., via torsion, via tight manufacturing tolerances, via a mating structure, etc.). In various embodiments, the electrical coupler 100 may have a circular opening 107 at its axial center, the opening 107 having two linear bosses forming a segment of the opening 107 defined by a linear chord. The segment may be formed of the same material as the electrical coupler 100. In various embodiments, the segment may be formed of a different material than the electrical coupler 100. In various embodiments, the segment may be integrally formed or attached after the electrical coupler 100 is manufactured. Accordingly, the catalytic element 308 may be formed with a prismatic end portion configured to enter the opening 107 between the segments. The catalytic element 308 can then be rotated (or otherwise engaged) to capture a segment of the electrical coupler 100 within a notch formed by the engagement in the prismatic end of the catalytic element 308. The segment can be configured to hold the catalytic element 308 in the axial direction of the electrical coupler 100. This mechanical interlocking technique is merely illustrative and is not intended to limit the types of mechanical connections between components described herein.

[0086] Figure 3C The diagram illustrates specific examples of the interface between electrical couplers 100a, 100b and catalytic element 308. Electrical couplers 100a, 100b can be formed as generally planar components with an arcuate cross-section sized to fit the end of catalytic element 308. For example, catalytic element 308 can have a circular end shape, thus electrical couplers 100a, 100b can have generally circular portions to abut against catalytic element 308. Electrical couplers 100a, 100b can have tab portions extending linearly from the center of the arcuate portion, configured to receive one or more electrical connections, such as alligator clips, bolt couplings, or the like. In various embodiments, the tab portions can be formed with a generally triangular cross-section. In various embodiments, the tab portions can be of any shape extending away from the end of catalytic element 308 to couple electrical connections to catalytic element 308. In various embodiments, the tab portions can have a power interface 108 disposed thereon, for example, as an opening sized to receive a cable. In various embodiments, the tabs can be features (rod-shaped, plate-shaped, or any other shape) that extend away from the catalytic element to engage with external electrical conductors in regions of the system with significantly lower temperatures (“cold zones”), enabling engagement with higher conductivity electrical feedthroughs (“hot zones”) that cannot withstand catalytic conditions close to the element.

[0087] In a specific example, the catalyst element 308 can be formed as a rectangular prism with a generally square cross-section (e.g., for example...). Figure 3D (As shown). Machined carbon (or other suitable electrocoupler material) can be formed into electrodes and bonded to the sides of the prismatic catalytic element (e.g., by means of a conductive adhesive, which can also be formed from carbon). These electrodes can be bonded to the catalytic element 308 on opposite sides, sandwiching the element between them. Alternatively or alternatively, machined alumina can be bonded to the catalytic element 308 on two additional sides. Alumina can be used due to its electrical insulating and thermally conductive properties. Alternatively or alternatively, all sides (e.g., faces) of the catalytic element 308 can be bonded to electrodes, a subset of the sides (such as opposite sides) can be bonded using a conductive carbon adhesive, and another pair of sides can be bonded using alumina cement or alumina paste, and / or other suitable bonding mechanisms can be used on other suitable surfaces (e.g., sides).

[0088] In a specific instance, the catalyst element 308 can be formed from a foam-like substrate (e.g., for example...). Figure 3E (As shown in the perspective and plan views). The foam substrate can be formed of one or more metals, refractory materials (e.g., ceramics), combinations thereof, and / or other suitable materials. The foam catalyst element 308 can be subjected to a thermally sprayed coating (e.g., nickel, Hastelloy, etc.) on at least one side. The thermally sprayed coating can be applied to any side of the catalyst element 308, including opposite and contrasting sides, or any arrangement having an electrical insulator.

[0089] In specific instances (such as, for example) Figure 3F As illustrated in the figure, a catalyst element-electrode assembly (e.g., a reaction module) may include a paste (e.g., carbon, silicon carbide, etc.) applied to the catalyst element 308 to bond tabs (e.g., nickel tabs) to opposite and opposite sides. The tabs can be formed in any shape or size, and are shown herein as foils having a rectangular planar shape. The catalyst element 308 may be formed as a rectangular prism with generally planar sides. On the opposite sides, the catalyst element 308 may be bonded to a graphite component using any paste / adhesive described herein. In various embodiments, the graphite component may have integrally formed or attached tabs for electrical connection via clamps.

[0090] In these specific instances (e.g., the first specific instance, the second specific instance, or the third specific instance), the electrical couplers 100a, 100b may have features that allow interaction with other external or internal systems as described above (e.g., ...). Figures 4A-4F(As shown). These features can be used to interact with external power supply lines (such as power interface 108), insulating components, fluid flow components 312, mechanical interface features 112 (e.g., for system stability), and / or other such systems. These features can also provide sealing surfaces for pressure vessel 304, insulating jackets, and / or other components. In various embodiments, one or more insulating jackets may be placed or coupled around reactor 300. In various embodiments, the insulating jackets may be electrically insulating and / or thermally insulating. In various embodiments, the insulating jackets may include structural components configured to couple, retain, or stabilize at least a portion of reactor 300. In various embodiments, the insulating jackets may be inside or outside the pressure vessel and may be used to electrically isolate various sub-components of the reactor system.

[0091] In a specific variation of the third specific example, reactor 300 can be mechanically connected via threaded rods extending from electrical couplers 100a and 100b (e.g., for example...). Figure 4B (As shown in the front view). The electrical coupler may have corresponding holes, wherein a straight rod may be located within two couplers and extend between the two couplers, the couplers being fastened to the rod. The electrical contact may be any electrical contact as described herein, such as a metal foam, gasket, spring, or the like. Reactor 300 may include a gasket configured to form a seal between the electrical coupler 100 and pressure vessel 304. A space (e.g., annular space) may exist between the catalytic element 308 and pressure vessel 304 or insulating jacket. In various embodiments, the pressure vessel and / or insulating jacket may have a thermocouple feeder 402 disposed therein, the thermocouple feeder 402 being configured to receive a thermocouple and allow electrical coupling to the outside of reactor 300. In other embodiments, the space may be filled with an inert insulating medium to restrict gas from bypassing the catalytic element.

[0092] In some variations of the example, reactor 400a (such as, for example, in...) Figure 4C(As shown in the front view) a tab coupling can be used between the electrocoupler 100a and the catalyst element 308 via a bolted connection. The tab 404 can be formed of tungsten (or other refractory metals, refractory materials, combinations thereof, etc.) and has an opening formed therein (e.g., configured to receive bolts or mechanical fasteners to form a connection with the electrocouplers 100a, 100b). The tab 404 can have a groove, hole, or combination thereof formed therein to receive mechanical fasteners of a corresponding shape passing through it. In various embodiments, any suitable bonding technique can be used to bond the tab 404 to the catalyst element. In various embodiments, the tab 404 can be formed of any conductive material. The reactor 400b can have electrocouplers 100a, 100b mechanically or chemically (or both) bonded to the catalyst element 308 as described herein. The electrocouplers 100a, 100b can be, for example, partially or entirely formed of graphite. In various embodiments, reactors 400a, 400b may have a graphite-based current-carrying thermal expansion joint 408 configured to maintain electrical connection between the electric coupler and the catalytic element during thermal expansion. The thermal expansion joint 408 may include one or more wires and / or other electrical connections configured to move and maintain the electrical connection during component movement such as expansion and / or contraction of the electric coupler 100a and / or the catalytic element. In various embodiments, the thermal expansion joint 408 may be configured to deliver current to the coupler 100a via discrete connections radially spaced around the coupler 100a to provide uniform heating and uniform expansion of the coupler 100a.

[0093] For example in Figures 4E-4GAs shown in the front and isometric views, these specific examples of reactor 400c (which may be identical to any of the aforementioned reactors with different numbers) may include an insulating jacket 412 disposed around the catalytic element 308 and the pressure vessel 304. In various embodiments, the insulating jacket 412 may be partially or entirely formed by the pressure vessel 304. In various embodiments, the insulating jacket 412 may physically contact the pressure vessel 304. In various embodiments, the insulating jacket 412 may be spaced apart from the pressure vessel 304 (e.g., forming an annular space between them). In various embodiments, the insulating jacket 412 may have the same planar shape as the pressure vessel 304, such as circular. In various embodiments, the insulating jacket 412 may have different planar shapes; for example, the pressure vessel may be cylindrical (with a circular cross-section), and the insulating jacket 412 may be prismatic with a rectangular cross-section. The insulating jacket 412 may have any number of thermocouple feeders 402 spaced radially along the axial direction or around the periphery. In various embodiments, an insulator may be alternatively or additionally disposed within the pressure vessel. In addition, the pressure vessel itself can be made of any material capable of withstanding the reaction conditions. For example, but not limited to, stainless steel, Inconel, refractory lined tubes (e.g., tubes made of steel, stainless steel, etc.) or other suitable materials can be used.

[0094] For example in Figures 4F-4G As shown, exemplary reactors 400d and 400e (which may be the same as or different from other exemplary reactors) may have pressure vessels separated by gap connections along the axial direction of reactors 400d and 400e. In various embodiments, pressure vessel 412 may be formed of any number of components and mechanically coupled together via one or more mechanical fasteners (such as nuts and bolts) threaded through corresponding flange holes. Reactor 400d is depicted having both a power interface 108 and a fluid flow interface 312 formed in a first end, while reactor 400e is depicted having fluid flow interfaces 312 disposed at both ends of the reactor. Pressure vessel 412 may be configured to have any number or type of interfaces for coupling to various external systems (e.g., sensors, gases, power sources, etc.). In these exemplary reactors, an insulator may be included between the pressure vessel wall and the catalytic element (and / or at other suitable locations within the reactor).

[0095] like Figure 1Figures 3 and 4 illustrate a schematic design of an electrical coupler (e.g., a cylindrical conductor, contactor, electrode) 100, with one side having a threaded connection for mating with a gas supply line, and the other side having a countersunk hole design for receiving a catalytic (resistive) element 308. The catalytic element 308 can be coupled to the electrical couplers 100a and 100b using mechanical bonding and / or chemical bonding techniques. The reactor 300 is shown having electrical couplers (contactors) 100a and 100b as described above. Additionally, the reactor 300 is shown having a fluid flow 312 flowing through a conduit coupled to the electrical coupler 100a. Those skilled in the art will understand that the threaded conduit connection shown is merely one example of a system and method for delivering process gas to the reactor 300.

[0096] An exemplary reactor 300 has a pressure vessel 304 that is hermetically coupled to electrical couplers 100a and 100b (e.g., forming an hermetically tight seal between them) and extends between the electrical couplers 100a and 100b. The electrical couplers 100a and 100b are shown coupled together via more than one electrically isolated threaded rod extending between them, which is secured in place by washers and nuts threaded onto opposite and opposing surfaces of each electrical coupler. However, other coupling mechanisms may be used. The reactor 300 has a catalytic element 308 disposed within the pressure vessel 304. The catalytic element 308 is shown as red and yellow due to its heat supplied by electrical energy provided through contact with one or both of the electrical couplers 100a and 100b. Those skilled in the art will understand that the description of the catalytic element 308, regardless of the illustrated colors, is not intended to limit it to the operating temperatures that the reactor 300 can withstand or optimize. Furthermore, those skilled in the art will understand that the illustrations herein are not intended to limit the types of reactions that may occur within reactor 300.

[0097] Interface 500 may include at least one opening 107 (e.g., such as...) Figure 5A , Figure 5C , Figure 5D and Figure 5E(The thread configuration is shown in the figure). In various embodiments (e.g., where at least one opening 107 is formed as more than one opening), each of the more than one opening may be radially spaced around the central axis of the electrical coupler 100, and each opening may be threaded or may utilize another mechanical interface. In some variations, the interface 500 may include a retaining screw 504. The retaining screw 504 may be configured to be threaded into at least one opening 107. The retaining screw 504 may be configured to enter the opening 107 from above (e.g., defined relative to FIG. 5) and rotate downward along the opening 107 until it approaches a second side of the electrical coupler 100, near the interface 105 (not shown). The retaining screw 504 may have a hexagonal opening formed therein, which is configured to mate with one or more standard tools, such as an Allen key, an Allen wrench, a Hex key, or similar tools. In various implementations, the retaining screw 504 may include geometric features configured to engage and couple with any number of tools, such as Phillips flathead screwdrivers, drill drivers, impact drivers, or similar tools.

[0098] In various embodiments, the retaining screw 504 may be formed of the same material as the electrocoupler 100. In various embodiments, the retaining screw 504 may be formed of any conductive material, partially insulating material, semiconductor material, combination of materials (e.g., alloy, cermet, etc.), and / or other suitable materials (e.g., electrocoupler material, substrate material, catalyst material, etc.). In various embodiments, the retaining screw 504 may have a similar or the same coefficient of thermal expansion as the electrocoupler 100 (e.g., formed of the same material).

[0099] In various embodiments, the retaining screw 504 has one or more openings 506 configured to allow fluid to flow through them. For example... Figure 5A and Figure 5BAs shown, the retaining screw 504 may include more than one regularly spaced opening on the side of the retaining screw near the catalyst element 308. Alternatively, a single opening 506 may be present. In various embodiments, any of the openings 506 may be irregularly shaped, regularly shaped, circular, elliptical, grooved, mesh / screen, and / or have any suitable structure. In various embodiments, the interface 500 may include a compression element 508 (e.g., a washer). In various embodiments, the compression element 508 may be compressed and driven into contact with the catalyst element 308 by rotation of the retaining screw 504. The compression element 508 may be formed of any material (e.g., catalyst material, substrate material, electrocoupler material, interface material, etc.). The compression element 508 may be configured to deform elastically or plastically in response to compression from the retaining screw 504. For example, the compression element 508 may be a disc spring or a Bavarian washer, wherein the washer is formed with angled surfaces such that the outer and inner peripheries are out of plane relative to each other. The retaining screw 504 can compress the periphery of the washer spaced apart from the top of the catalyst element 308, causing the washer to deform downwards, and ensuring contact between the electrical coupler 100 and the catalyst element 308 by the spring resistance of the washer against compression. In another example, the compression element 508 can be a metal foam. The metal foam can have a spring constant or shape memory, such that when compressed downwards by the retaining screw 504, the metal foam resists the compression and is pressed back between the retaining screw 504 and the catalyst element 308, thereby maintaining electrical communication between them. In various embodiments, the compression element 308 can be a helical spring, a leaf spring, an internal or external toothed washer, a spiral washer, a corrugated washer, a split lock washer, a fender washer, a flat washer, or the like.

[0100] As an illustrative example, compression element 508 may be a gasket. The gasket may be attached to catalyst element 308 and pressed against electrical coupler 100. In various embodiments, electricity may flow from the electrical coupler to compression element 508, to catalyst element 308, to second compression element 508, and to second electrical coupler 100. In various embodiments, compression element 508 may be attached to catalyst element 308 via a carbon paste.

[0101] For example Figure 6 As shown, a multi-unit reactor system (e.g., reactor 600) may include more than one electrical coupler and catalytic element (e.g., reaction module). In this example of the reactor, a larger contact at the end can provide an interface for reactant gas delivery and product gas outlet, while an intermediate electrical coupler can utilize a dielectric intermediate component (e.g., a quartz tube) to achieve sealing and electrical isolation between adjacent units.

[0102] An exemplary reactor 600 may include one or more reactors 300 disposed therein. For example, but not limited to, reactor 600 may include any number of units, each unit being formed by a separate reactor 300. Reactor 600 may be a two-unit reactor system with multiple electrical couplers arranged to create a single fluid flow path via multiple resistive elements arranged in series with an external power supply line interface. For example, reactor 300a may have an electrical coupler 100a shown at the top, wherein pressure vessel 304a is hermetically coupled to electrical coupler 100a, wherein pressure vessel 304a contains a catalytic element 308a therein. In examples of multi-unit reactors, each unit may be fluidly connected through a common pressure vessel 304 and / or the reaction units may be fluidly isolated. Pressure vessel 304 may extend from reactor 304a to reactor 304b, wherein electrical couplers 100b, 100c are positioned between the proximal and distal ends of reactor 600 for internal sealing and inter-unit isolation. Alternatively or alternatively, each reactor 300a, 300b may have a separate pressure vessel in fluid communication with each other. For example, but not limited to, a first pressure vessel 304a may extend from a first electrical coupler 100a to a second electrical coupler 100b, wherein each coupler contacts a catalytic element within pressure vessel 304a. Alternatively or alternatively, a bridge-type pressure vessel 604 may extend between the second electrical coupler 100b and a third electrical coupler 100c. The second pressure vessel 304b may then extend from the third electrical coupler 100c to a fourth electrical coupler 100d, wherein a second catalytic element 308b is electrically connected to both the third electrical coupler 100c and the fourth electrical coupler 100d. Catalytic elements 308a and 308b may extend within the pressure vessel between the electrical couplers; for example, catalytic element 308a may extend from 100a to 100b, and catalytic element 308b may extend from 100c to 100d. In various embodiments, each unit may have its own pressure vessel, which is fluidly and / or electrically isolated from each other (e.g., each pressure vessel has its own fluid inlet). In various embodiments, each unit of reactor 600 may operate at a different temperature. In various embodiments, a common negative electrode may be used in a multi-unit system to improve volumetric efficiency. For example, two units connected in series may use a shared contact as a common ground to minimize space in reactor 600.

[0103] In various implementation schemes (e.g., for...) Figure 7As shown in the exemplary radial reactor 700, one or more power interfaces can be electrically connected to one or more of the electrical couplers 704a, 704b. In various embodiments, electrical coupler 704a can be a positive electrode, and electrical coupler 704b can be a negative electrode. In various embodiments, each electrical coupler 704a, 704b can be electrically connected to a separate power source. In various embodiments, electrical couplers 704a can be electrically connected to each other, with current flowing through each of the electrical couplers 704a. In various embodiments, electrical couplers 704a can have different resistances or material properties and are configured to uniformly heat the radial reactor 700 from a single power interface. For example, but not limited to, end electrical couplers 704a can have a lower resistance than intermediate electrical couplers 704a, such that each electrical coupler provides uniform heat to the catalytic element. In various embodiments, each of the radial electrical couplers 704a, 704b can be configured such that current flows radially across the element. The power interface can be configured to be electrically connected to one or more patterned fingers.

[0104] In various embodiments, the radial reactor 700 may include one or more longitudinal baffles 708. The baffles 708 may be formed of one or more ceramics (and / or other suitable electrically insulating materials). In various embodiments, the baffles 708 may have the same radius as each of the electrical couplers 704a, 704b, and electrically isolate the electrical couplers 704a, 704b from each other. The baffles 708 may extend from the distal end to the proximal end of the radial electrical coupler 700, thereby providing both structural rigidity, electrical isolation, and fluid flow directionality. In various embodiments, fluid flows through a porous inlet 712 across the longitudinal axis of the radial electrical coupler 700. The baffles 708 may be configured to guide the fluid flow longitudinally through the central portion of the reactor 700.

[0105] Examples of radial reactor 700 may include more than one annular element 716, each annular element 716 associated with an electrical coupler 704a, 704b. In various embodiments, each electrical coupler 704a, 704b and / or a subset thereof may have an electrical coupling interface for electrical connection to one or more wires or other current-carrying devices. In various embodiments, the electrical coupling interface may include tabs, holes, clamps, or the like. In various embodiments, the catalyst element 716 may be the same as or similar to the catalyst element 308 (and / or other catalyst elements described herein). In various embodiments, adjacent elements may have the same or different materials. In various embodiments, one or more components, such as a current distributor, may be connected to each catalyst element 716 such that patterned fingers will physically abut and compress. In various embodiments, each of the catalyst elements 716 may be electrically and / or fluidly connected in series. In various embodiments, each catalyst element 716 may be electrically and / or fluidly connected in parallel. In various embodiments, a first portion of the catalyst element 716 may be connected in series, and a second portion may be connected in parallel. In various embodiments, fluid may flow around the exterior of the radial coupler 700 and / or through the stack to form the catalytic elements 716 of the radial coupler 700. In various embodiments, each catalytic element 716 in the stack may be heated by its corresponding electrical coupler 704a, 704b. In various embodiments, each catalytic element 716 may be selectively heated by its electrical coupler 704a, 704b at a different rate than adjacent or other catalytic elements 716. In various embodiments, each electrical coupler 704a, 704b may operate independently of the other electrical couplers. In various embodiments, each catalytic element 716 may be sized or configured to be uniformly heated by one or more electrical couplers 704a, 704b. In various embodiments, the resistance of each catalytic element 716 may be adjusted (e.g., by geometry, material selection, etc.). For example, but not limited to, the catalytic elements 716 may be formed with varying densities based on the longitudinal position of the radial reactor 700 or the longitudinal position within the radial reactor 700. The radial reactor 700 may have a porous fluid outlet 720 disposed opposite to the fluid inlet 712. In various embodiments, the fluid outlet 720 may be configured similarly to the fluid inlet 712. The fluid inlet 712 and the fluid outlet 720 may be generally circular or arcuate planar shapes. In various embodiments, the fluid inlet 712 and the fluid outlet 720 may be formed to completely cover the circular ends of the electrical coupler 716. In various embodiments, the fluid inlet 712 and the fluid outlet 720 may be mechanically coupled to the partition 708 and / or the catalytic element 716 adjacent thereto.

[0106] In a first illustrative example of a thermal reactor, the thermal reactor may include a reaction module comprising: a first electrode; a catalytic element; and a second electrode; wherein the catalytic element is disposed between the first and second electrodes, wherein the catalytic element is resistively heated to a temperature greater than about 1000°C by a current supplied between the first and second electrodes, wherein fluid flows through the first electrode into the catalytic element; wherein the first and second electrodes define the flow distribution of the fluid through the catalytic element. In a variation of the first illustrative example, the pressure drop of the fluid through the first electrode is less than the pressure drop of the fluid through the catalytic element.

[0107] In a second illustrative example, the catalytic element described in the first illustrative example may include a substrate and a catalytic material disposed on the substrate, the substrate comprising a refractory material, wherein the substrate comprises a high surface area.

[0108] In the third illustrative example, the refractory material described in the second illustrative example may include at least one of the following: silicon carbide, tungsten, molybdenum, molybdenum disilicide, tungsten carbide, titanium carbide, graphite, molybdenum carbide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, chromium carbide, tantalum carbide, rhenium carbide, rhodium carbide, ruthenium carbide, osmium carbide, or iridium carbide.

[0109] In the fourth illustrative example, the first and second electrodes described in the first, second, or third illustrative examples may include at least one of the following: silicon carbide, tungsten, molybdenum, molybdenum disilicide, tungsten carbide, titanium carbide, graphite, molybdenum carbide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, chromium carbide, tantalum carbide, rhenium carbide, rhodium carbide, ruthenium carbide, osmium carbide, or iridium carbide.

[0110] In the fifth illustrative example, the substrate in any one of the second, third, or fourth illustrative examples may include a foam-like material.

[0111] In the sixth illustrative example, the first electrode and the second electrode, as described in any one of the first, second, third, fourth, or fifth illustrative examples, are mechanically connected to the catalytic element such that current flows through the catalytic element between the first electrode and the second electrode.

[0112] In the seventh illustrative example, the first and second electrodes of any one of the first, second, third, fourth, fifth, or sixth illustrative examples are adhered to the catalytic element using an adhesive, wherein current flows between the first and second electrodes through the adhesive and the catalytic element. In a variation of the seventh illustrative example, the first and second electrodes are connected to the catalytic element via a chemical bond (e.g., the first electrode, second electrode, and catalytic element are manufactured as a single object).

[0113] In the eighth illustrative example, the first electrode in any one of the first, second, third, fourth, fifth, sixth, or seventh illustrative examples defines a through-hole through which fluid flows.

[0114] In the ninth illustrative example, the first electrode in any one of the first, second, third, fourth, fifth, sixth, or seventh illustrative examples includes a mesh, through which fluid flows.

[0115] In the tenth illustrative example, the first electrode, the catalytic element, and the second electrode in any one of the first, second, third, fourth, fifth, sixth, seventh, eighth, or ninth illustrative examples each have substantially the same cross-sectional dimensions and the same cross-sectional shape.

[0116] In the eleventh illustrative example, the fluid in any one of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, or tenth illustrative examples includes hydrogen, carbon monoxide, carbon dioxide, and water vapor.

[0117] In the twelfth illustrative example, the thermal reactor in any one of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, or eleventh illustrative examples further includes a second reaction module, wherein the second reaction module is arranged in a flow parallel to the reaction module.

[0118] In the thirteenth illustrative example, the second electrode in any one of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, or twelfth illustrative examples is arranged upstream of the catalytic element relative to the fluid flow.

[0119] In the fourteenth illustrative example, the reaction module (or its catalytic element) in any one of the first, second, third, fourth, fifth, sixth, seventh, eighth, ninth, tenth, eleventh, twelfth, or thirteenth illustrative examples comprises a U-shape or a V-shape.

[0120] In the fifteenth illustrative example, a method for operating a thermal reactor includes flowing a fluid over or through a catalyst element; and heating the catalyst element to at least a threshold temperature using resistance heating; wherein, before flowing the fluid over or through the catalyst element, the fluid flows through a void space defined by electrodes, wherein the electrodes provide current to the catalyst element for resistance heating of the catalyst element.

[0121] In the sixteenth illustrative example, the catalytic element described in the fifteenth illustrative example includes a substrate and a catalytic material disposed on the substrate, the substrate including a refractory material, wherein the substrate includes a high surface area.

[0122] In the seventeenth illustrative example, the refractory material described in the sixteenth illustrative example includes at least one of the following: silicon carbide, tungsten, molybdenum, molybdenum disilicide, tungsten carbide, titanium carbide, graphite, molybdenum carbide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, chromium carbide, tantalum carbide, rhenium carbide, rhodium carbide, ruthenium carbide, osmium carbide, or iridium carbide.

[0123] In the eighteenth illustrative example, the first and second electrodes described in the fifteenth, sixteenth, or seventeenth illustrative examples include at least one of the following: silicon carbide, tungsten, molybdenum, molybdenum disilicide, tungsten carbide, titanium carbide, graphite, molybdenum carbide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, chromium carbide, tantalum carbide, rhenium carbide, rhodium carbide, ruthenium carbide, osmium carbide, or iridium carbide.

[0124] In the nineteenth illustrative example, the substrate of any one of the sixteenth, seventeenth, or eighteenth illustrative examples comprises a foam-like substance.

[0125] In the twentieth illustrative example, the fluid in any one of the fifteenth, sixteenth, seventeenth, eighteenth, or nineteenth illustrative examples includes hydrogen, carbon monoxide, carbon dioxide, and water vapor.

[0126] In the twenty-first illustrative example, the catalytic element or (single or more) electrical coupler described in any one of illustrative examples 1-14 may be used (independently or together) for applications other than or as alternatives to thermal reactors, such as air or other fluid purifiers, carbon capture, electrolysis, electroplating, etc.

[0127] In the twenty-second illustrative example, an electrical coupler (e.g., for a reactor system with resistance heating) includes: an electrical conductor and at least one opening, the electrical conductor having a first end and a second end, a thickness defined between the first end and the second end, the first end and the second end having a first interface in the first end and a second interface in the second end, respectively, and the at least one opening extending from the first end to the second end, the at least one opening being configured to allow fluid to flow through the electrical coupler.

[0128] In the twenty-third illustrative example, the resistance-heated reactor includes: a proximal end having a planar porous gas inlet; at least one catalytic element having a first end and a second end, wherein a sidewall extends between the first end and the second end; a first electrical contactor having a first end and a second end, a contactor sidewall defined between the first end and the second end, the contactor sidewall being configured to externally connect a first portion of the sidewall of the at least one catalytic element; a second electrical contactor having a first end and a second end, a contactor sidewall defined between the first end and the second end, the contactor sidewall being configured to externally connect a second portion of the sidewall of the at least one catalytic element, the second electrical contactor being laterally spaced from the first electrical contactor; a first partition disposed between the first electrical contactor and the second electrical contactor externally connecting at least one catalytic element; a second partition disposed between the first electrical contactor and the second electrical contactor externally connecting at least one catalytic element, the second partition being spaced apart from the first partition; and a distal end having a planar porous gas outlet.

[0129] In the twenty-fourth illustrative example, the resistance-heated reactor described in the twenty-third illustrative example further includes: more than one catalytic element axially aligned from proximal to distal end; and more than one corresponding first and second electrical contactors external to each catalytic element, wherein the first and second electrical contactors are separated by a first and a second partition extending from the proximal end to the distal end, external to a portion of each catalytic element.

[0130] In the twenty-fifth illustrative example, a resistance-heated reactor includes: a pressure vessel having a first vessel end and a second vessel end, wherein a sidewall is externally connected to the first vessel end and the second vessel end and extends between the first vessel end and the second vessel end; a first electrical coupler disposed at the first vessel end, the first electrical coupler having a first electrical conductor and at least one opening, the first electrical conductor having a first end and a second end, a thickness defined between the first end and the second end, the at least one opening extending from the first end to the second end, the at least one opening being configured to allow fluid to flow through it into the pressure vessel; a second electrical coupler disposed at the second vessel end, the second electrical coupler having a second electrical conductor and at least one opening, the second electrical conductor having a third end and a fourth end, a thickness defined between the third end and the fourth end, the at least one opening extending from the third end to the fourth end, the at least one opening being configured to allow fluid to flow from the pressure vessel through the second electrical coupler; and a catalytic element disposed within the pressure vessel, the catalytic element being in contact with the first electrical coupler and the second electrical coupler.

[0131] In the twenty-sixth illustrative example, the electrical coupler described in any one of the twenty-second to twenty-fifth illustrative examples, wherein the electrical conductor is formed of refractory metal.

[0132] In the twenty-seventh illustrative example, the electrical coupler described in the twenty-sixth illustrative example, wherein the refractory metal is at least one of tungsten, molybdenum, niobium, tantalum and / or alloys thereof.

[0133] In the twenty-eighth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to twenty-seventh illustrative examples, wherein the conductive material is a metal.

[0134] In the twenty-ninth illustrative example, the electrical coupler or thermal reactor described in the twenty-eighth illustrative example, wherein the metal is at least one of nickel, copper, gold, titanium, aluminum, or stainless steel.

[0135] In the thirtieth illustrative example, the electrical coupler or thermal reactor described in any one of the twenty-second to twenty-ninth illustrative examples, wherein the electrical conductor is conductive ceramic.

[0136] In the thirty-first illustrative example, the electrical coupler or thermal reactor described in the thirty-tenth illustrative example, wherein the conductive ceramic is at least one of silicon carbide, tungsten carbide, niobium carbide and / or titanium carbide.

[0137] In the thirty-second illustrative example, the electrical coupler or thermal reactor described in any one of the twenty-second to thirty-first illustrative examples, wherein the electrical conductor is formed of a composite material.

[0138] In the thirty-third illustrative example, the electric coupler or thermal reactor described in the thirty-second illustrative example, wherein the composite material is a metal ceramic.

[0139] In the thirty-fourth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to thirty-third illustrative examples is provided, wherein the electric coupler is formed from a single continuous body.

[0140] In the thirty-fifth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to thirty-fourth illustrative examples, wherein at least one opening is a borehole formed perpendicular to the first end and the second end, the borehole having a diameter of about 0.5 cm to 10 cm.

[0141] In the thirty-sixth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to thirty-fourth illustrative examples, wherein at least one opening is formed from a first end to a second end, and each of the more than one opening has a diameter of about 0.01 cm to 5 cm.

[0142] In the thirty-seventh illustrative example, the electrical coupler or thermal reactor described in the thirty-sixth illustrative example, wherein more than one opening is formed in a ring arranged concentrically with a normal axis extending from the center of the first end to the center of the second end.

[0143] In the thirty-eighth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to thirty-fourth illustrative examples, wherein at least one opening is formed in the electric coupler as a metallic foam having more than one channel passing through it.

[0144] In the thirty-ninth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to thirty-eighth illustrative examples further includes at least one electrical interface.

[0145] In the fortieth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to thirty-ninth illustrative examples further includes at least one fastener interface.

[0146] In the forty-first illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty illustrative examples, wherein the first end and the second end each comprise a circular planar shape.

[0147] In the forty-second illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-first illustrative examples is provided, wherein the electric coupler is formed from a single continuous body.

[0148] In the forty-third illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-second illustrative examples, wherein the pressure vessel forms a seal with each of the first and second electric couplers.

[0149] In the forty-fourth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-third illustrative examples, wherein each of the first and second electric couplers has a cylindrical shape formed concentrically with the pressure vessel.

[0150] In the forty-fifth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-fourth illustrative examples, wherein at least one of the first and second electric couplers has at least one electrical interface.

[0151] In the forty-sixth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-fifth illustrative examples, wherein at least one of the first and second electric couplers has at least one fastener interface.

[0152] In the forty-seventh illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-sixth illustrative examples, wherein the first and second electric couplers are coupled via at least one threaded rod extending between them and parallel to the pressure vessel.

[0153] In the forty-eighth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-seventh illustrative examples, wherein the catalytic element contacts the first electric coupler via a fixing screw in a threaded hole of the first electric coupler, the fixing screw being configured to compress the compression element against the catalytic element.

[0154] In the forty-ninth illustrative example, the electrical coupler or thermal reactor described in the forty-eighth illustrative example, wherein the compression element is a gasket.

[0155] In the fiftieth illustrative example, the electrical coupler or thermal reactor described in the forty-ninth illustrative example, wherein the gasket is a Bausch washer or a disc spring.

[0156] In the fifty-first illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-eight illustrative examples, wherein the compression element is a metal foam.

[0157] In the fifty-second illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to fifty-first illustrative examples further includes a thermocouple.

[0158] In the fifty-third illustrative example, a thermal reactor includes two or more resistance-heated reactors (e.g., the resistance-heated reactors of any one of the twenty-second to fifty-second illustrative examples) fluidly coupled in series, wherein fluid leaving the first reactor enters the second reactor.

[0159] In the fifty-fourth illustrative example, the electrical coupler or thermal reactor described in the fifty-third illustrative example, wherein each resistance-heated reactor has a common pressure vessel extending between them.

[0160] In the fifty-fifth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to fifty-fourth illustrative examples, wherein the first electric coupler and / or the second electric coupler are formed from a single continuum.

[0161] In the fifty-sixth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to forty-fifth illustrative examples or the fifty-second to fifty-fifth illustrative examples, wherein at least one of the first and second electric couplers and the catalytic element are integrally formed.

[0162] In the fifty-seventh illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to fifty-fifth illustrative examples, wherein at least one of the electric couplers is formed by combined components.

[0163] In the fifty-eighth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to fifty-seventh illustrative examples, wherein the pressure vessel is cylindrical.

[0164] In the fifty-ninth illustrative example, the electric coupler or thermal reactor described in any one of the twenty-second to fifty-seventh illustrative examples, wherein the pressure vessel is prismatic.

[0165] While the disclosed subject matter is described herein with reference to certain preferred embodiments, those skilled in the art will recognize that various modifications and improvements can be made to the disclosed subject matter without departing from the scope thereof. Furthermore, although features of one embodiment of the disclosed subject matter may be discussed herein or shown in the accompanying drawings of one embodiment but not in other embodiments, it should be apparent that features of one embodiment may be combined with one or more features of another embodiment or features from more than one embodiment.

[0166] In addition to the specific embodiments claimed below, the disclosed subject matter also relates to other embodiments having any other possible combinations of the dependent features claimed below and those disclosed above. Therefore, the specific features presented in the dependent claims and disclosed above may be combined with each other in other ways within the scope of the disclosed subject matter, such that the disclosed subject matter should be considered to also specifically relate to other embodiments having any other possible combinations. Therefore, for purposes of illustration and description, the foregoing description of specific embodiments of the disclosed subject matter has been presented. It is not intended to be exhaustive or to limit the disclosed subject matter to those disclosed embodiments.

[0167] It will be apparent to those skilled in the art that various modifications and variations can be made to the methods and systems disclosed without departing from the spirit or scope of the disclosed subject matter. Therefore, the disclosed subject matter is intended to include modifications and variations within the scope of the appended claims and their equivalents.

[0168] Implementations of the system and / or method may include every combination and arrangement of various system components and various methodological processes, wherein one or more instances of the methods and / or processes described herein may be performed asynchronously (e.g., sequentially), synchronously (e.g., concurrently, in parallel, etc.), or in any other suitable order by means of and / or using one or more instances of the systems, elements, and / or entities described herein. Components and / or processes of the foregoing systems and / or methods may be used together with, in addition to, or in lieu of, all or part of the systems and / or methods disclosed in the applications mentioned above, replacing or otherwise integrating with all or part of the systems and / or methods, each of which is incorporated herein by reference in its entirety.

[0169] As used herein, “basically” or other similar terms (e.g., “about”, “approximately”, etc.) may be interpreted within a predetermined error threshold or tolerance of a measure, component, or other reference value (e.g., within 0.001%, 0.01%, 0.1%, 1%, 5%, 10%, 20%, 30% of the reference value) or may be interpreted otherwise.

[0170] As will be apparent to those skilled in the art from the foregoing detailed description and from the accompanying drawings and claims, modifications and alterations may be made to the preferred embodiments of the invention without departing from the scope of the invention as defined in the appended claims.

Claims

1. A thermal reactor comprising: a reaction module comprising: a first electrode; a catalytic element; and a second electrode; wherein the catalytic element is disposed between the first electrode and the second electrode, wherein the catalytic element is resistively heated to a temperature greater than about 1000°C by an electrical current provided between the first electrode and the second electrode, wherein the first electrode and the second electrode determine a flow profile of a fluid through the catalytic element.

2. The thermal reactor of claim 1, wherein the catalytic element comprises a substrate and a catalytic material disposed on the substrate, the substrate comprising a refractory material, wherein the substrate comprises a high surface area.

3. The thermal reactor of claim 2, wherein the refractory material comprises at least one of silicon carbide, tungsten, molybdenum, tungsten carbide, titanium carbide, graphite, molybdenum carbide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, chromium carbide, tantalum carbide, rhenium carbide, rhodium carbide, ruthenium carbide, osmium carbide, or iridium carbide.

4. The thermal reactor of claim 3, wherein the first electrode and the second electrode comprise at least one of silicon carbide, tungsten, molybdenum, tungsten carbide, titanium carbide, graphite, molybdenum carbide, molybdenum disilicide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, chromium carbide, tantalum carbide, rhenium carbide, rhodium carbide, ruthenium carbide, osmium carbide, or iridium carbide.

5. The thermal reactor of claim 1, wherein the first electrode and the second electrode are at least one of: mechanically connected to the catalytic element such that an electrical current flows through the catalytic element between the first electrode and the second electrode; adhered to the catalytic element using an adhesive, wherein an electrical current flows through the adhesive and the catalytic element between the first electrode and the second electrode; or connected to the catalytic element by a chemical bond.

6. The thermal reactor of claim 5, wherein the first electrode, the second electrode, and the catalytic element are fabricated as a single object.

7. The thermal reactor of claim 1, wherein the first electrode defines a through-hole, wherein the fluid flows through the through-hole.

8. The thermal reactor of claim 1, wherein the first electrode comprises a mesh, wherein the fluid flows through interstices in the mesh.

9. The thermal reactor of claim 1, wherein the first electrode, the catalytic element, and the second electrode each have substantially the same cross-sectional size and the same cross-sectional shape.

10. The thermal reactor of claim 1, wherein the fluid comprises hydrogen, carbon monoxide, carbon dioxide, and water vapor.

11. The thermal reactor of claim 1, further comprising a second reaction module, wherein the second reaction module is arranged in a flow stream parallel to the reaction module.

12. The thermal reactor of claim 1, wherein the second electrode is arranged upstream of the catalytic element relative to a fluid flow.

13. The thermal reactor of claim 15, wherein the reaction module comprises a U-shape or a V-shape.

14. The thermal reactor of claim 1, wherein the fluid flows through the first electrode into the catalytic element; wherein a pressure drop of the fluid through the first electrode is less than a pressure drop of the fluid through the catalytic element.

15. A method for operating a thermal reactor, comprising: flowing a fluid over or through a catalytic element; and heating the catalytic element to at least a threshold temperature using resistive heating; wherein prior to flowing the fluid over or through the catalytic element, the fluid flows through a void space bounded by an electrode, wherein the electrode provides electrical current to the catalytic element for resistive heating of the catalytic element.

16. The method of claim 15, wherein the catalytic element comprises a substrate and a catalytic material disposed on the substrate, the substrate comprising a refractory material, wherein the substrate comprises a high surface area.

17. The method of claim 16, wherein the refractory material comprises at least one of silicon carbide, tungsten, molybdenum, molybdenum disilicide, tungsten carbide, titanium carbide, graphite, molybdenum carbide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, chromium carbide, tantalum carbide, rhenium carbide, rhodium carbide, ruthenium carbide, osmium carbide, or iridium carbide.

18. The method of claim 17, wherein the first electrode and the second electrode comprise at least one of silicon carbide, tungsten, molybdenum, molybdenum disilicide, tungsten carbide, titanium carbide, graphite, molybdenum carbide, zirconium carbide, hafnium carbide, vanadium carbide, niobium carbide, chromium carbide, tantalum carbide, rhenium carbide, rhodium carbide, ruthenium carbide, osmium carbide, or iridium carbide.

19. The thermal reactor of claim 18, wherein the substrate comprises a foam.

20. The method of claim 15, wherein the fluid comprises hydrogen, carbon monoxide, carbon dioxide, and water vapor.

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