Fluid-Cooled Reformer Using Fuel-Stream Reformate Cooling
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Solution Overview
Problem
The high temperatures generated by fuel reforming systems in gas turbines pose a challenge for cooling the reformer and the heated reformate stream, requiring expensive high-temperature materials and adding complexity with additional cooling systems.
Innovation Solution
A fluid cooled reformer system that uses a portion of the fuel stream to cool both the reactor assembly and the heated reformate stream, mixing the fuel stream with the reformate to reduce its temperature to a level that can be handled by low-cost, low-temperature piping materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fuel reforming systems are used to produce hydrogen-rich gas, then combustion stability and emissions performance are improved, but the high temperature reformate stream exceeds the allowable temperature for standard piping materials
Solution Approach 1:
A heat exchanger is introduced as an intermediary component between the reformer and the piping system. The heat exchanger transfers heat from the high-temperature reformate stream to a cooling fluid, thereby mediating the temperature reduction while allowing the reformer to operate at optimal high temperatures for hydrogen production
Solution Approach 2:
The system uses a portion of the incoming fuel stream itself as the cooling fluid in the heat exchanger. This self-service approach eliminates the need for external cooling systems, as the fuel stream serves dual purposes: as reactant and as coolant, thereby reducing system complexity and cost
2Temperature
If high-temperature materials are used for downstream piping to handle the heated reformate stream, then the system can operate at high temperatures, but material costs significantly increase
Solution Approach 1:
The heat exchanger acts as an intermediary that decouples the high-temperature reforming process from the low-temperature piping system. By transferring heat to a cooling fluid, the reformate stream temperature is reduced to levels compatible with standard, low-cost piping materials, eliminating the need for expensive high-temperature alloys
Solution Approach 2:
The system employs standard, inexpensive piping materials for the downstream piping network by cooling the reformate stream before it enters the piping system. This approach replaces expensive, specialized high-temperature materials with common, readily available materials, significantly reducing manufacturing costs
3Temperature
If additional cooling systems such as heat exchangers are added to cool the reformer and reformate stream, then temperature control is improved, but system complexity and expense increase
Solution Approach 1:
The fuel stream is given multiple functions: it serves as the reactant for hydrogen production and simultaneously as the cooling fluid in the heat exchanger. This multi-functionality eliminates the need for separate, dedicated cooling systems, thereby reducing overall system complexity while maintaining effective temperature control
Solution Approach 2:
The system cools itself by using a portion of its own fuel supply as the cooling medium. This self-service cooling approach eliminates the need for external cooling utilities, separate coolant loops, and additional control systems, thereby simplifying the overall system architecture while achieving the required temperature control
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 provides a cost-effective and simplified cooling method for gas turbines, enhancing combustion efficiency, reducing emissions, and improving operability by increasing hydrogen levels in the fuel stream, while allowing for the use of standard piping materials.
Implementation Method 1
at least a portion of the fluid stream may be used to cool the reactor assembly
Implementation Method 2
mixing the heated reformate stream with the fluid stream to cool the heated reformate stream
Data Source
AI summary
The present subject matter discloses a fluid cooled reformer for gas turbine systems and a method for cooling both a fuel reformer and a heated reformate stream produced by such fuel reformer. The fluid cooled reformer may include a pressure vessel and a reactor assembly disposed within the pressure vessel. The reactor assembly may include a reactor and may be configured to receive and reform an oxygen/fuel mixture to produce a heated reformate stream. Additionally, the fluid cooled reformer may include an inlet configured to direct a fluid stream into the pressure vessel. At least a portion of the fluid stream may be used to cool the reactor assembly. A reformate cooling section may be disposed downstream of the reactor of the reactor assembly and may be configured to cool the heated reformate stream.