Concentric Filter Element for Hydrocarbon Fuel Purification
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Solution Overview
Problem
Current systems for filtering hydrocarbon fuels, particularly for fuel cell applications, face challenges in efficiently separating and enriching light end hydrocarbons while reducing sulfur and other impurities, which can lead to coking and poisoning of catalytically-active metals in fuel cell systems.
Innovation Solution
A closed loop filtration system and method that uses a filter element with concentric layers of filtration media, including size exclusion materials and sulfur removal components, to continuously separate and enrich light end hydrocarbons, reducing sulfur and other impurities from mixed hydrocarbon fuels, allowing for the production of a liquid reformable fuel product suitable for fuel cell systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional filtration systems are used to remove sulfur-containing compounds from liquid fuels, then sulfur content is reduced, but light end hydrocarbons are not effectively separated and enriched
Solution Approach 1:
The filtration system is divided into multiple functional layers: a first layer containing sulfur removal media (such as zinc oxide or activated carbon) and a second layer containing molecular sieves or zeolites for light end hydrocarbon separation. This segmentation allows each layer to perform its specific function optimally, achieving both sulfur removal and light end hydrocarbon enrichment simultaneously
Solution Approach 2:
Different regions of the filter element are assigned different filtration properties - the first layer is optimized for sulfur compound removal with chemically active media, while the second layer is optimized for physical separation of light end hydrocarbons using molecular sieves with specific pore sizes. This local quality differentiation enables precise control over what each section removes or retains
2Reliability
If filtration media is used to remove impurities, then sulfur and contaminants are reduced, but system complexity increases
Solution Approach 1:
The system merges sulfur removal and light end hydrocarbon separation functions into a single integrated filter element. The multiple layers are combined in one component that can be installed in the existing fuel delivery system, protecting fuel cell catalysts from both sulfur poisoning and coking without requiring multiple separate filtration systems
Solution Approach 2:
The filter element acts as an intermediary component between the liquid reformable fuel storage and the fuel reformer. It pre-treats the fuel by removing sulfur and enriching light end hydrocarbons before the fuel enters the reformer, thereby protecting the catalytically active metals from degradation while simplifying the overall system architecture
3Manufacturing precision
If liquid reformable fuel is filtered to enrich light end hydrocarbons, then fuel quality improves, but processing time increases
Solution Approach 1:
The filter element is pre-configured with optimized layer thicknesses and media selections during manufacturing. The first layer with sulfur removal media and the second layer with molecular sieves are pre-assembled in specific configurations that enable effective filtration in a single pass through the filter, minimizing processing time while achieving the desired fuel composition control
Solution Approach 2:
The filtration system is designed to operate continuously as fuel flows through the reformable fuel tank and filter assembly. The closed-loop system maintains constant circulation of fuel through the filter element, ensuring continuous enrichment of light end hydrocarbons and removal of sulfur without interrupting fuel supply to the reformer
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
The system provides a steady state supply of liquid reformable fuel enriched in light end hydrocarbons with reduced sulfur content, minimizing the deleterious impact on fuel cell components and enabling immediate or stored use, with adjustable parameters for specific applications.
Implementation Method 1
At least one of the layers of filtration media includes a size exclusion material. The size exclusion material can be designed such that lighter end hydrocarbons in the mixture of hydrocarbons can pass through the filtration media
Implementation Method 2
The layers of filtration media can include other components to reduce the content of or remove impurities such as metals such as heavy metals, alkali metals, and alkaline earth metals
Data Source
Figure 1A
Figure 1B
Figure 2A~2C
AI summary
Closed loop filtration systems and methods of the present teachings can provide liquid reformable fuels enriched in light end hydrocarbons and/or having reduced content of sulfur and/or other impurities. Such enriched liquid reformable fuels can be used in fuel cell systems having a vaporizer and hydrocarbon fuel reformer such that the fuel cell system can experience less deleterious impact on its components, for example, coking. Filter elements for use in the systems and methods also are provided.