Continuous Liquid Fuel Reforming via Atomization and Monolith Catalyst
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Solution Overview
Problem
Current methods for reforming liquid hydrocarbon fuel to increase its cetane number are inefficient, requiring batch mode reactors with long reaction times, high temperatures, and constant monitoring, making them impractical for continuous or on-board fuel reforming.
Innovation Solution
A continuous mode reactor system that uses a mixing zone with an atomizing nozzle to create droplets of liquid hydrocarbon fuel suspended in an oxygen-containing gas, which are then distributed through a monolith block with a stationary N-hydroxyphthalimide (NHPI) catalyst, allowing for efficient chemical reactions to produce a reformed fuel with a higher cetane number.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch mode reactor with solid particulate catalyst is used, then fuel reforming can be performed, but reaction time is long and continuous operation is not achievable
Solution Approach 1:
The patent implements continuous fuel reforming by circulating liquid fuel through a loop reactor containing stationary catalyst particles. The system maintains continuous contact between fuel and catalyst via circulation pump, enabling uninterrupted reaction and eliminating the need for batch processing. This resolves the contradiction by making the useful action continuous rather than intermittent.
Solution Approach 2:
The patent employs dynamic circulation of liquid fuel through the reactor loop, where fuel flows continuously past the stationary catalyst particles. The circulation pump creates dynamic movement of fuel through the reaction zone, maintaining active contact between reactants and catalyst throughout the system, thereby achieving continuous operation.
2Temperature
If batch mode reactor with solid particulate catalyst is used, then fuel reforming can be performed, but high temperatures and constant monitoring are required
Solution Approach 1:
The system uses the heat generated by the exothermic oxidation reaction itself to maintain the reaction temperature. The circulating fuel is heated by the reaction exotherm within the loop reactor, eliminating the need for external heating systems and constant temperature monitoring. The reaction self-regulates its temperature through the circulation and heat transfer within the closed loop.
3Reliability
If solid particulate catalyst is used in batch mode, then fuel reforming can be performed, but separation of catalyst from reaction mixture is required
Solution Approach 1:
The patent merges the catalyst particles with the liquid fuel circulation system by suspending catalyst particles throughout the circulating fuel stream. The catalyst remains dispersed in the liquid phase throughout the loop reactor, eliminating the need for separation processes. The catalyst and fuel form a unified circulating mixture that maintains continuous contact.
Solution Approach 2:
The patent employs porous catalyst particles that can be suspended in the liquid fuel stream. The porous structure allows the catalyst particles to remain dispersed and active within the liquid phase while maintaining their catalytic function. This enables the catalyst to be integrated into the circulation system without requiring separation.
4Productivity
If continuous mode reactor with stationary catalyst is used, then continuous fuel reforming is achieved, but strong interaction between catalyst, fuel, and oxygen is difficult to maintain
Solution Approach 1:
The patent creates dynamic interaction between stationary catalyst and circulating fuel by continuously moving the fuel through the catalyst bed. The circulation pump maintains constant flow of fuel past the stationary catalyst particles, ensuring continuous fresh fuel contact with the catalyst surface. This dynamic circulation maintains high reaction efficiency while preserving continuous operation.
Solution Approach 2:
The patent uses hydraulic circulation of liquid fuel through the reactor system. The circulation pump creates continuous liquid flow through the loop reactor, forcing fuel to pass through the catalyst bed. This hydraulic circulation ensures strong and continuous interaction between the circulating fuel, stationary catalyst, and dissolved oxygen, maintaining high reaction 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 system enables continuous reforming of liquid hydrocarbon fuels with a higher cetane number, improving engine efficiency and reducing emissions, particularly during cold starts, by shortening ignition delays and ensuring complete fuel combustion.
Implementation Method 1
The at least one atomizing nozzle may generate a plurality of droplets comprising the liquid hydrocarbon fuel, where the droplets are suspended in the oxygen-containing gas
Implementation Method 2
a reforming catalyst coated onto the monolith walls in the plurality of flow channels
Implementation Method 3
contacting the plurality of droplets with the oxygen-containing gas in the presence of the reforming catalyst
Data Source
AI summary
According to one or more other aspects of the present disclosure, a system for reforming a liquid hydrocarbon fuel includes a mixing zone with a fuel intake fluidly coupled to a liquid hydrocarbon fuel source and an oxygen-containing gas intake fluidly coupled to an oxygen-containing gas source. The mixing zone further includes at least one atomizing nozzle and a fuel distribution zone downstream the at least on atomizing nozzle. The system also includes a catalyst reaction zone downstream the mixing zone, including a monolith block having a plurality of flow channels defined by monolith walls and a reforming catalyst coated onto the monolith walls. The atomizing nozzle generates a plurality of droplets comprising the liquid hydrocarbon fuel suspended in oxygen-containing gas. The fuel distribution zone distributes the plurality of droplets to each of the plurality of flow channels to contact the reforming catalyst including N-hydroxyphthalimide.