Patent ID: 7622088

Claim:
A reactor for rapid start-up, comprising: a catalyst support structure having a surface with one or more regions overlaid with an active coating comprising a catalyst, wherein said active coating heats upon exposure to a non-thermal energy source; and a generator of non-thermal energy for applying said non-thermal energy to said active coating, wherein said catalyst support structure is an open structured porous foam with a tortuous flow pattern that enhances non-thermal energy penetration and facilitates penetration of one or more reactants introduced to the reactor and said regions are located on a surface of said tortuous flow pattern, wherein said active coating further comprises an active material that heats upon exposure to said non-thermal energy source and said active coating comprises a first layer and a second layer, wherein said first layer comprises said active material and is disposed on said one or more regions of said surface of said catalyst support structure and said second layer comprises said catalyst and is disposed on said first layer with said first layer between said second layer and said support structure.