Finned Alcohol Reformer Catalyst for Rapid Startup
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Solution Overview
Problem
Alcohol reforming technologies face challenges in achieving efficient heat transfer and maintaining catalytic activity while minimizing thermal mass, which affects the rapid startup and performance of alcohol-fueled vehicles, particularly due to issues like methanation reactions and backpressure from catalysts.
Innovation Solution
The use of copper-nickel catalysts with a finned design that incorporates thermally conductive materials and structured catalysts, such as copper-plated nickel sponge, embedded in metal mesh or felt, along with internal filters to prevent catalyst movement and enhance heat transfer from exhaust gases to the catalyst, allowing for efficient reforming of alcohols like methanol and ethanol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional catalyst beds are used for alcohol reforming, then catalytic activity is achieved, but thermal mass is high which slows startup time
Solution Approach 1:
The catalyst is segmented into small particles distributed throughout a porous support structure rather than using a solid catalyst bed. This segmentation reduces the thermal mass while maintaining catalytic surface area, enabling faster heatup and quicker startup time for the reforming process.
Solution Approach 2:
A porous support structure is used to hold the catalyst particles. The porous material provides high surface area for catalyst distribution while having low thermal mass. The porous structure allows rapid heat penetration and distribution throughout the catalyst, significantly reducing startup time compared to traditional dense catalyst beds.
2Productivity
If catalysts are used to promote reforming reactions, then alcohol conversion is improved, but backpressure increases which reduces engine performance
Solution Approach 1:
The porous support structure provides numerous flow pathways for the reforming gases to pass through. This多孔 structure reduces flow resistance and backpressure compared to dense catalyst beds, while still providing sufficient catalytic activity for high alcohol conversion rates. The porous architecture allows easy gas permeability maintaining engine performance.
Solution Approach 2:
The catalyst is distributed locally throughout the porous support structure rather than forming a continuous dense bed. This local distribution maintains catalytic activity where needed while creating open pathways elsewhere for gas flow, thereby reducing backpressure. The local quality approach optimizes both conversion and pressure drop characteristics.
3Use of energy by moving object
If heat transfer surface area is increased to improve heat transfer efficiency, then reforming rate increases, but device complexity and size increase
Solution Approach 1:
The porous support structure inherently provides extremely high surface area within a compact volume. This porous architecture delivers large heat transfer surface area without increasing device size or complexity, as the porosity itself creates the extensive surface area needed for efficient heat transfer from the support to the catalyst particles.
Solution Approach 2:
The system uses a composite structure combining the porous support material with dispersed catalyst particles. This composite architecture integrates heat transfer and catalytic functions in a single component, eliminating the need for separate heat exchange structures and reducing overall device complexity while maintaining high heat transfer efficiency.
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 approach enables rapid heatup of the reformer, maintains high catalytic activity, reduces backpressure, and improves heat transfer efficiency, allowing for higher engine efficiency and lower NOx emissions by suppressing methanation reactions and optimizing temperature distribution.
Implementation Method 1
a heat transfer member (74) in thermal contact with the conduit (170) and the alcohol reforming catalyst, whereby heat is transferable from the plurality of fins (22) to the alcohol reforming catalyst
Implementation Method 2
Alcohol reforming can be an endothermic catalytic process that converts alcohols to a mixture of hydrogen and other gases
Implementation Method 3
heat from the exhaust gas flowing in the exhaust chamber is transferable from the plurality of fins (22) to the alcohol reforming catalyst
Data Source
AI summary
Reforming alcohol is disclosed. Alcohol is introduced into a conduit of an alcohol reformer so that the alcohol flows through a catalyst stage within the conduit. The catalyst stage includes an alcohol reforming catalyst, and a heat transfer member comprising thermally conductive material. The heat transfer member is in thermal contact with the conduit and the alcohol reforming catalyst. Simultaneously, exhaust gas is introduced from an internal combustion engine into an exhaust channel. The exhaust gas in the exhaust channel contacts fins extending outward from the conduit so that heat from the exhaust gas is transferred through the fins, the conduit, and the heat transfer member to the alcohol reforming catalyst.