Fuel Processor Mixing Partition Plate Design
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Solution Overview
Problem
Conventional fuel processors face challenges in achieving efficient mixing of hydrogen-containing gas and air due to complex shapes, leading to increased manufacturing costs, pressure loss, and reduced mixing capability, which can result in insufficient CO removal and catalyst poisoning, limiting power generation capacity.
Innovation Solution
A fuel processor design that divides the air mixing space into an outer and inner passage using a partition plate, allowing for a longer mixing distance without increasing pressure loss, and enabling effective mixing through optimized side hole and gas outlet sizes, reducing the need for complex shapes and manual welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air mixing space is extended to improve mixing capability, then mixing distance increases, but pressure loss increases
Solution Approach 1:
The air mixing space is divided into an outer passage and an inner passage using a partition plate. This segmentation allows the gas flow to be distributed across multiple pathways, increasing the effective mixing distance without proportionally increasing the pressure loss. The partition plate creates parallel flow paths that enhance mixing efficiency while maintaining acceptable pressure characteristics.
2Reliability
If complex shapes are used to improve mixing, then mixing capability increases, but manufacturing cost increases
Solution Approach 1:
Instead of using complex three-dimensional shapes, the invention segments the mixing space into simple cylindrical passages (outer and inner passages) separated by a partition plate. This segmentation approach achieves effective mixing through the simplified geometric configuration, avoiding the need for complex manufacturing processes while maintaining mixing capability.
Solution Approach 2:
The invention transitions from attempting to achieve mixing through complex radial or axial shape variations to using a dimensional approach with concentric cylindrical passages. The partition plate creates a radial dimension for flow distribution, allowing simple cylindrical geometries to achieve effective mixing that would otherwise require complex shapes.
3Reliability
If complex shapes are used to improve mixing, then mixing capability increases, but device complexity increases
Solution Approach 1:
The mixing space is segmented into outer and inner passages by a partition plate, creating a structurally simple yet functionally effective configuration. This segmentation avoids complex three-dimensional geometries while achieving the desired mixing capability through the organized division of flow paths.
Solution Approach 2:
The partition plate serves multiple functions: it divides the mixing space into outer and inner passages, provides structural support, and facilitates the radial distribution of gas flow. This multi-functionality reduces the need for additional components, thereby simplifying the overall device structure while maintaining mixing effectiveness.
4Reliability
If manual welding is used to fix components, then reliability increases, but productivity decreases
Solution Approach 1:
The partition plate is designed as a separate component that divides the mixing space, allowing it to be manufactured independently and then assembled. This segmentation enables the use of standardized joining methods and simplifies the assembly process, potentially allowing for automated assembly techniques rather than manual welding, thereby improving productivity while maintaining connection reliability.
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 design achieves high mixing capability with reduced manufacturing costs and pressure loss, ensuring stable CO removal and extended system operation with minimal CO concentration, even under deteriorated conditions, and maintaining robustness over long continuous operation.
Implementation Method 1
source gas and steam are supplied into the reformer... source gas is steam reformed by the action of the reforming catalyst into the hydrogen containing gas
Implementation Method 2
carbon monoxide (CO) in gas is reduced by the action of the CO converter catalyst
Implementation Method 3
CO is removed by the action of the CO removal catalyst... 2CO + O2 → 2CO2
Implementation Method 4
A heating unit 5 is provided at the center of the fuel processor 1. The heating unit 5 includes a heat chamber 3 containing a burner 2
Implementation Method 5
Source gas 70 supplied to an inlet 6a of the first gas passage 6 is mixed at the inlet 6a of the first gas passage 6 with reformed water 72 supplied through a heating coil 15... The source gas 70 and the reformed water 72 are heated through the first gas passage 6 acting as an evaporator
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A fuel processor is provided with a mixing part including a mixing passage having a sufficient distance without increasing a pressure loss, at low cost with a small number of manufacturing steps. A partition plate (200) having tilted portions is provided in the air mixing space of the mixing part (16), thereby dividing the air mixing space into multiple passages (201, 202) so as to extend the mixing passage. Hence, high mixing capability can be obtained with a simple configuration.