Helical Thread Reactor for Portable Fuel Desulfurization

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Solution Overview

Problem

Conventional desulfurization systems for solid oxide fuel cell (SOFC) generators are complex and heavy, making them unsuitable for portable use in military field deployments, where logistic fuels like diesel and JP-8 require effective sulfur removal to prevent poisoning of anodes and fuel reformers.

Innovation Solution

A compact, lightweight reactor with an inner and outer helical thread fuel path design that uses a metal oxide sorbent material and a heating element to efficiently remove sulfur from liquid hydrocarbon fuels, allowing for horizontal orientation and efficient desulfurization performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional desulfurization systems are used, then sulfur removal effectiveness is achieved, but system weight and complexity increase

Engineering Contradiction:

Improvesulfur removal effectivenessVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent combines the heating element, sorbent material containment, and fuel flow path into a single integrated reactor assembly. The helical fuel path is formed by engaging an inner helical thread portion with an outer helical thread portion, creating a compact structure that eliminates the need for separate heating units, sorbent vessels, and flow control mechanisms found in conventional systems.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The inner helical thread portion is nested within the outer helical thread portion, with the heating element positioned within the inner helical thread. This nested configuration allows the fuel to flow through a helical path while being heated by the central heating element and contacting the sorbent material lining the fuel path, achieving multiple functions in a compact nested structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If conventional desulfurization systems are used, then sulfur removal effectiveness is achieved, but device complexity increases

Engineering Contradiction:

Improvesulfur removal effectivenessVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reactor assembly serves multiple functions simultaneously: the heating element provides thermal energy for the desulfurization reaction, the helical thread structure creates the fuel flow path and mixing action, and the sorbent material contacts the fuel to remove sulfur. This multi-functional design reduces the number of separate components needed in conventional systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Quantity of substance

If refractory sulfur compounds are present in fuel, then fuel energy density is maintained, but sulfur removal difficulty increases

Engineering Contradiction:

Improvefuel energy densityVSAvoiddesulfurization difficulty

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent changes the temperature parameter by incorporating a heating element that raises the fuel temperature to optimize the desulfurization reaction. The helical fuel path also creates enhanced mixing and contact between the fuel and sorbent material, effectively changing the mass transfer parameters to improve removal of refractory sulfur compounds like dimethylbenzothiophene and trimethylbenzothiophene.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a metal oxide sorbent material that is specifically effective for removing refractory sulfur compounds from hydrocarbon fuels. The combination of the heated environment, helical flow pattern, and metal oxide sorbent creates a composite desulfurization system that maintains fuel energy density while effectively removing difficult sulfur species.

Inventive Principle:

Principle #40Composite materials

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 system effectively reduces sulfur levels from 700 ppmw to less than 1 ppmw, achieving 99.8% desulfurization efficiency and providing a portable, re-assembly capable, and efficient desulfurization solution for military fuel applications.

Implementation Method 1

The heating element is utilized to raise the temperature of the fuel path such that when the liquid hydrocarbon fuel contacts the metal oxide sorbent material, sulfur is removed effectively from the liquid hydrocarbon fuel

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

contacting the liquid hydrocarbon fuel with a metal oxide sorbent material in the fuel path

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS9238781B2Systems and methods for liquid fuel desulfurization

Publication Date: 2016.01.19 UNIVERSITY OF SOUTH CAROLINA

AI summary

In one aspect, the present subject matter is directed to a system for removing sulfur from liquid hydrocarbon fuel. The system includes a reactor having a fuel inlet and fuel outlet. The fuel inlet and fuel outlet are in fluid communication with a fuel path passing through the reactor. The fuel path is defined by an inner helical thread portion and an outer helical thread portion. The inner helical thread portion is complimentary with and has a smaller diameter than the outer helical thread portion. The inner helical thread portion surrounds a heating element and the outer helical thread portion is surrounded by an outer cover.