Fuel Processor Reactor Integration for Reliable Hydrogen Supply
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Solution Overview
Problem
Fuel cell arrangements face challenges at low electrical load conditions and open circuit conditions due to lack of steam for low-temperature steam reforming and dependency of hydrodesulphurization on anode off gas recirculation rates, which vary with operating conditions.
Innovation Solution
A fuel processor comprising a desulphurisation reactor, catalytic partial oxidation reactor, combustor, and pre-reformer, which supplies safe gas, synthesis gas, and processed hydrocarbon fuel to the fuel cell arrangement in different operational modes, including desulphurization, catalytic partial oxidation, and pre-reforming, independent of fuel cell load conditions, using hydrogenolysis to convert higher hydrocarbons to methane without requiring external steam or careful control of reaction conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If low temperature steam reforming is used in the pre-reformer, then the hydrocarbon fuel can be reformed at lower temperatures, but steam is not available at low electrical load conditions or open circuit conditions
Solution Approach 1:
A water-gas shift reactor is introduced as an intermediary component between the catalytic partial oxidation reactor and the pre-reformer. This reactor receives carbon monoxide and water from the partial oxidation reactor and converts them to hydrogen and carbon dioxide through the water-gas shift reaction, providing a reliable steam source independent of fuel cell load conditions.
Solution Approach 2:
The system performs preliminary water-gas shift reaction in a dedicated reactor before the pre-reforming stage. This preliminary action converts carbon monoxide to additional hydrogen and generates steam in advance, ensuring steam availability is decoupled from the fuel cell's operational steam demand.
2Reliability
If hydrodesulphurisation is performed using anode off gas recirculation, then sulphur can be removed from the hydrocarbon fuel, but the process becomes dependent on fuel cell operating conditions
Solution Approach 1:
The desulphurisation function is segmented from the fuel cell system into a separate catalytic partial oxidation reactor. This reactor dedicatedly performs hydrodesulphurisation using its own catalyst bed, making the sulphur removal process independent of anode off gas recirculation rates and fuel cell operating conditions.
Solution Approach 2:
A dedicated catalytic partial oxidation reactor serves as an intermediary desulphurisation unit. It receives hydrocarbon fuel, performs partial oxidation with controlled air supply to generate hydrogen in-situ for desulphurisation, and removes sulphur independently before the fuel enters the pre-reformer.
3Reliability
If multiple reactors are integrated for desulphurisation, partial oxidation, and pre-reforming, then consistent fuel supply can be ensured under varying conditions, but the device complexity increases
Solution Approach 1:
Multiple functional reactors (catalytic partial oxidation reactor with desulphurisation catalyst, water-gas shift reactor, and pre-reformer) are merged into a single integrated fuel processor assembly. They share common housing, heat exchange networks, and control systems, reducing overall system complexity while maintaining functional independence for reliable fuel supply.
Solution Approach 2:
The integrated reactor assembly performs multiple functions simultaneously: desulphurisation, water-gas shift, and pre-reforming. Each reactor is designed with multi-functionality, such as the partial oxidation reactor that both generates hydrogen and removes sulphur, reducing the need for separate dedicated components.
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 solution ensures consistent fuel supply to fuel cells under varying conditions, reduces sulphur content, and simplifies the processing by integrating reactors for efficient heat management and minimizing energy loss, while maintaining high efficiency and reducing parts complexity.
Implementation Method 1
a desulphurisation reactor (12), means to supply a hydrocarbon fuel to the desulphurisation reactor, the desulphurisation reactor being arranged to supply desulshurised hydrocarbon fuel
Implementation Method 2
a catalytic partial oxidation reactor (14), means to supply air to the catalytic partial oxidation reactor, the catalytic partial oxidation reactor being arranged to supply the pre-reformer
Implementation Method 3
catalytic partial oxidation on the desulphurised hydrocarbon fuel to produce a synthesis gas
Implementation Method 4
a combustor (16), means to supply air to the combustor, the combustor being arranged to supply oxygen depleted air and steam to the pre-reformer
Implementation Method 5
using hydrogenolysis to convert higher hydrocarbons to methane
Implementation Method 6
low temperature steam reforming of the hydrocarbon fuel
Data Source
AI summary
The fuel processor (10) comprises a desulphurization reactor (12), a catalytic partial oxidation reactor (14), a combustor (16) and a pre-reformer (18), means (20) to supply a hydrocarbon fuel to the desulphurization reactor (12), means (24) to supply air to the catalytic partial oxidation reactor (14) and means (24) to supply air to the combustor (16). The desulphurization reactor (12) is arranged to supply desulphurised hydrocarbon fuel to the catalytic partial oxidation reactor (14) in first, second and third modes of operation, to the combustor (16) in a first mode of operation to the pre-reformer (18) in a third mode of operation. The combustor (16) is arranged to supply oxygen depleted air and steam to the pre-reformer (18) in the first mode of operation. The catalytic partial oxidation reactor (14) is arranged to supply hydrogen to the desulphurization reactor (12) in all three modes of operation. The catalytic partial oxidation reactor (14) is arranged to supply the pre-reformer (18) in all three modes of operation and the pre-reformer (18) is arranged to supply product gases to the fuel cell arrangement.