Autothermal Reformer Startup via Partial Oxidation
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Solution Overview
Problem
Fuel reformers, particularly those using autothermal reforming, face challenges in starting up efficiently without prematurely degrading the reformer catalyst, especially when using diesel fuel due to unstable temperature distributions.
Innovation Solution
A method involving sequential heat supply using a fluid containing oxygen, a fuel, and a catalyst to initiate a partial oxidation reaction within the autothermal reformer, followed by controlling temperature with a cooling fluid, adjusts flow rates of these fluids to stabilize the catalyst and initiate autothermal reforming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If autothermal reforming is used to start up the fuel reformer, then external heat supply is reduced, but the reformer catalyst may be prematurely spent due to unstable temperature distribution
Solution Approach 1:
The patent applies preliminary action by preheating the reformer catalyst using a heating element before initiating autothermal reforming. This ensures the catalyst reaches a stable operating temperature gradually, preventing thermal shock and premature degradation while enabling subsequent self-sustained reforming without excessive external heat supply
Solution Approach 2:
The patent implements dynamics by dynamically adjusting the flow rates of fuel and oxidant during the start-up process. The control system modulates these flows to maintain stable temperature distribution in the catalyst bed, preventing hot spots that would degrade the catalyst while transitioning from external heating to autothermal operation
2Quantity of substance
If steam reforming is used to obtain hydrogen, then hydrogen yield is improved, but the reactor design becomes complicated due to large heat consumption
Solution Approach 1:
The patent merges steam reforming and partial oxidation reforming into a single autothermal reforming process. This combination allows the exothermic partial oxidation reaction to provide the heat required for the endothermic steam reforming reaction, achieving high hydrogen yield while simplifying reactor design by eliminating the need for separate external heating systems and steam generation equipment
3Use of energy by stationary object
If partial oxidation reforming is used to acquire hydrogen, then external heat supply is eliminated, but hydrogen yield is lower than steam reforming
Solution Approach 1:
The patent combines steam reforming and partial oxidation reforming in an autothermal reforming process. The partial oxidation provides the necessary heat without external supply, while the steam reforming component ensures high hydrogen yield by reacting steam with hydrocarbon fuel over the catalyst, achieving both energy self-sufficiency and high hydrogen production
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively starts the fuel reformer, protects the catalyst from degradation, and achieves efficient autothermal reforming by generating heat through partial oxidation, reducing the need for external heat and stabilizing the reformer temperature.
Implementation Method 1
contacting a first fluid comprising oxygen with the heating element, passing the first fluid into the autothermal reformer to preheat a reformer catalyst contained within the autothermal reformer to a first temperature
Implementation Method 2
introducing a fuel into the autothermal reformer subsequent to preheating the reformer catalyst to initiate a partial oxidation reaction within the autothermal reformer to generate additional heat
Implementation Method 3
Partial oxidation reforming is a method of acquiring hydrogen by an exothermic reaction of fuel and oxygen
Implementation Method 4
controlling the temperature of the reformer catalyst by supplying a cooling fluid, the first fluid, and the fuel to the autothermal reformer and adjusting flow of each of the cooling fluid, the first fluid, and the fuel
Data Source
AI summary
In accordance with one or more embodiments of the present disclosure, a method of starting a fuel reformer including a heating element and a subsequent autothermal reformer includes contacting a first fluid comprising oxygen with the heating element, passing the first fluid into the autothermal reformer to preheat a reformer catalyst within the autothermal reformer to a first temperature, reducing flow of the first fluid into the autothermal reformer, introducing a fuel into the autothermal reformer subsequent to preheating the reformer catalyst to initiate a partial oxidation reaction and generating additional heat, increasing flow of the fuel and first fluid to initiate autothermal reforming, and controlling the temperature of the reformer catalyst by supplying a cooling fluid, the first fluid, and the fuel and adjusting flow of each.