Flex-Fuel H2 Reformer Using Autothermal Reforming
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Solution Overview
Problem
Current internal combustion engines and gas turbines face challenges in reducing pollutants like unburned hydrocarbons, CO, NOx, and diesel particulates, with existing solutions such as catalytic converters and on-board reformers experiencing issues like coke formation and short lifespan due to unsteady state operations.
Innovation Solution
The development of an on-board Flex-Fuel H2 reforming apparatus using autothermal reforming (ATR) technology, which produces H2 and CO from hydrocarbons and bio-fuels over supported Pt group catalysts, with an automatic control system to maintain optimal O2/C, H2O/C, and CO2/C ratios, allowing for self-starting without external heat and power, and storing high-pressure reformate for efficient combustion and catalyst regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If on-board reformers use homogeneous partial oxidation reactions or very low activity catalysts to produce H2 from gasoline, then hydrogen production is achieved, but the reformers become bulky and coke formation occurs in the reaction zones
Solution Approach 1:
The patent changes the fundamental reaction parameters by switching from homogeneous partial oxidation to autothermal reforming (ATR) with steam injection. This parameter change enables high-activity catalytic reactions at lower temperatures, allowing compact reformer design without coke formation. The steam-to-carbon ratio and temperature control are key parameter adjustments that enable both compact size and high hydrogen production.
Solution Approach 2:
The patent introduces steam as an intermediary substance that facilitates the reforming reaction. Steam acts as a reactant that converts carbon-containing compounds into hydrogen and carbon monoxide, preventing direct carbon deposition (coke) on the catalyst. This intermediary approach enables high hydrogen production in a compact reformer by mediating the conversion process.
2Quantity of substance
If on-board reformers use homogeneous partial oxidation reactions or very low activity catalysts to produce H2 from gasoline, then hydrogen production is achieved, but coke formation occurs in the reaction zones
Solution Approach 1:
The patent converts the potential harm of carbon deposition into benefit by using steam reforming chemistry. Instead of allowing direct carbon formation, the introduced steam reacts with carbon species to produce hydrogen and carbon monoxide. This transforms what would be a harmful byproduct (coke) into useful hydrogen fuel, eliminating coke formation while enhancing hydrogen production.
Solution Approach 2:
The patent changes the reaction environment parameters by introducing steam and controlling the steam-to-carbon ratio. This parameter change fundamentally alters the reaction pathway from carbon-forming partial oxidation to carbon-converting steam reforming, thereby preventing coke formation while maintaining high hydrogen production rates.
3Object-generated harmful factors
If catalytic converters and NOx traps are used to reduce pollutants, then emission reduction is achieved, but the system requires complex electronic and mechanical devices for controlling air/fuel ratio and ignition timing
Solution Approach 1:
The patent makes the reformer catalyst perform multiple functions: it simultaneously produces hydrogen fuel and reduces pollutant emissions through the reforming reaction. This multi-functionality eliminates the need for separate catalytic converters and complex control systems, as the same catalyst bed achieves both fuel generation and emission reduction.
Solution Approach 2:
The patent merges the fuel production function and emission reduction function into a single integrated system. The reformer that produces hydrogen also inherently reduces CO and unburned hydrocarbons through the reforming reaction, combining what were previously separate functions (fuel production and emission control) into one unified process.
4Quantity of substance
If previous on-board reformers were used, then hydrogen production was achieved, but they had short lifespan due to coke formation and unsteady state operations
Solution Approach 1:
The patent implements feedback control by monitoring the steam-to-carbon ratio and adjusting operational parameters to maintain optimal reforming conditions. This feedback mechanism ensures stable operation during transient states, preventing the unsteady conditions that previously caused coke formation and shortened reformer lifespan.
Solution Approach 2:
The patent ensures continuous stable operation by maintaining optimal steam-to-carbon ratios and controlling the reforming process to avoid transient unsteady states. This continuity of proper chemical action prevents intermittent coke formation events, thereby extending the reformer's operational lifespan while maintaining continuous 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 solution effectively reduces pollutant emissions, improves engine efficiency, and extends the lifespan of catalysts by maintaining reaction temperatures below 1200°C, enabling stable operation under transient conditions and providing a compact, durable solution for mobile and stationary applications.
Implementation Method 1
produces H2 and CO from hydrocarbons and bio-fuels over supported Pt group catalysts
Implementation Method 2
using autothermal reforming (ATR) technology, which produces H2 and CO from hydrocarbons and bio-fuels
Implementation Method 3
maintain optimal O2/C, H2O/C, and CO2/C ratios, allowing for self-starting without external heat and power
Implementation Method 4
maintaining reaction temperatures below 1200°C, enabling stable operation under transient conditions
Data Source
AI summary
An on-board Flex-Fuel H2 reforming apparatus provides devices and the methods of operating these devices to produce a combustible reformate containing H2 and CO from hydrocarbons and bio-fuels. For this generator, one or more parallel autothermal reformers are used to convert the fuels into the reformate over Pt group metal catalysts, and the produced reformate is then cooled, compressed and stored in vessels at a pressure between 1 to 100 atmospheres. The reformate from the storage vessels is used either as the sole fuel or is mixed with other fuels as the fuel mixture for a lean burn engine/gas turbine. For this system, the pressure of the storage vessels and the flow control curves are used directly to control the amount of the reformers' reformate flow output.