Hydrogen Generator Cold Start Using Preheated Partial Oxidation
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Solution Overview
Problem
Existing hydrogen generators struggle to start from cold conditions within the required time frame, leading to inefficient catalytic converters and high emissions during the initial operation of internal combustion engines, which hampers compliance with environmental standards and fuel efficiency improvements.
Innovation Solution
A catalytic partial oxidation reactor with a metal mesh substrate and a heat source is energized at a specific power level, and fuel and oxidant are introduced simultaneously at a targeted O/C ratio, followed by de-energizing the heat source upon observing an incipient exotherm, allowing for a fast start in less than 6 seconds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the hydrogen generator starts from cold conditions using conventional methods, then the engine can operate, but the start-up time exceeds 6 seconds leading to high emissions and poor fuel efficiency
Solution Approach 1:
The heat source is activated before fuel introduction to pre-heat the catalyst and reactor components. This preliminary heating action ensures the catalyst reaches operational temperature quickly when fuel is introduced, enabling fast cold start-up within 6 seconds and reducing hydrocarbons emissions during the critical initial operation period
Solution Approach 2:
The patent optimizes the heat source power level (5-15% of fuel energy input), oxidant-to-fuel ratio (O/C between 0.8/1 and 1.3/1), and temperature parameters to achieve rapid heating during cold start-up. These parameter optimizations enable the system to reach steady-state temperature quickly, reducing emissions while maintaining fuel efficiency
2Speed
If the heat source is energized at high power to reduce start-up time, then cold start performance improves, but energy consumption and potential fuel deposits increase
Solution Approach 1:
The patent specifies that the heat source should be energized at a power level of 5-15% of the fuel energy input, not maximum power. This optimized parameter range provides sufficient heating rate for fast cold start-up while avoiding excessive energy consumption and fuel deposit formation that would occur at higher power levels
Solution Approach 2:
The heat source is activated continuously from cold start-up through the initial heating phase, ensuring consistent thermal input that prevents fuel condensation and deposit formation. This continuous heating action maintains efficient combustion conditions throughout the transition from cold start to steady-state operation
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 process enables a hydrogen generator to start from cold conditions in under 6 seconds, reducing harmful emissions and improving fuel efficiency during the critical initial engine operation, while minimizing fuel deposits and stabilizing the engine operation.
Implementation Method 1
a heat source disposed in proximity to a front face of the substrate; energizing the heat source at a power equal to about 5 to 15 percent of a power (energy) input to the reactor
Implementation Method 2
a substrate having a partial oxidation catalyst supported thereon; capable of reforming a mixture of a fuel and an oxidant into a mixture of hydrogen and carbon monoxide
Implementation Method 3
catalytic partial oxidation reactor capable of reforming a mixture of a fuel and an oxidant into a mixture of hydrogen and carbon monoxide
Implementation Method 4
upon observation of an incipient exotherm indicative of hydrogen generation, de-energizing the heat source
Data Source
AI summary
A process of quickly starting a hydrogen generator from cold conditions. The generator, which converts a fuel and an oxidant under catalytic partial oxidation conditions into a mixture of hydrogen and carbon monoxide, is intended for onboard integration with an internal combustion engine (ICE) of a transportation vehicle. Fast start of the hydrogen generator allows for rapid hydrogen augmentation of the ICE with the advantages of a more stable combustion and a reduction in hydrocarbon and NOx emissions.