Integrated Hydrogen Generator and Compressor Using Waste Heat
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Solution Overview
Problem
Current methods for producing hydrogen for fuel cell electric vehicles are inefficient and costly, particularly in scaling up hydrogen production for local refueling stations, due to the high energy consumption and greenhouse gas emissions associated with steam-methane reforming, and the expense of high-pressure gas compressors.
Innovation Solution
An integrated hydrogen generator and compressor apparatus that combines a steam-methane reformer with a gas compressor, utilizing waste heat from combustion cylinders to efficiently produce and compress hydrogen to 10,000 psi, reducing energy consumption and costs by integrating the production and compression processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If steam-methane reforming is used to produce hydrogen, then hydrogen can be produced from natural gas, but energy consumption is high and greenhouse gas emissions occur
Solution Approach 1:
The patent combines the steam-methane reformer with a gas compressor into an integrated system. The reformer produces hydrogen while the compressor compresses both natural gas and hydrogen within the same system, eliminating the need for separate compression systems and reducing overall energy consumption.
Solution Approach 2:
The patent utilizes waste heat from the combustion cylinders to provide the thermal energy needed for the steam-methane reforming process. This converts what would otherwise be wasted thermal energy into a useful resource for driving the endothermic reforming reaction, thereby reducing external energy requirements.
2Stress or pressure
If high-pressure gas compressors are used to compress hydrogen to 10,000 psi, then hydrogen can be prepared for fuel cell vehicles, but equipment cost is high
Solution Approach 1:
The patent integrates the gas compressor functionality directly into the reformer system, combining two previously separate expensive equipment items (reformer and compressor) into a single integrated unit. This reduces the total equipment cost while maintaining the capability to produce and compress hydrogen to 10,000 psi.
Solution Approach 2:
The integrated system performs multiple functions within a single apparatus: it produces hydrogen through reforming, compresses the natural gas feedstock, and compresses the produced hydrogen. This multi-functionality eliminates the need for separate dedicated compression equipment, reducing overall system cost.
3Productivity
If reformer systems are scaled up for local refueling stations, then hydrogen can be produced on-site, but cost becomes prohibitive
Solution Approach 1:
The patent creates a compact integrated system where the reformer and compressor are combined into a single unit. This integration reduces the overall system cost for local refueling stations by eliminating the need for separate compression equipment and reducing infrastructure requirements, making scaled-up deployment more economically viable.
4Quantity of substance
If hydrogen is transported via tank trucks, then high-pressure hydrogen can be delivered to refueling stations, but safety concerns and cost increase
Solution Approach 1:
The patent produces and compresses hydrogen on-site at the refueling station before it is needed for vehicle refueling. This preliminary production action eliminates the need for transporting hazardous high-pressure hydrogen through the public infrastructure system, thereby removing safety risks associated with tank truck transport while maintaining delivery capability.
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 solution enables efficient and cost-effective production of high-pressure hydrogen at a moderately sized scale, reducing the carbon footprint and eliminating the need for hazardous hydrogen transport, making it suitable for widespread refueling locations.
Implementation Method 1
steam-methane reforming (SMR), a mature production process in which high-temperature steam (700° C.-1,000° C.) is used to produce hydrogen from a methane source
Implementation Method 2
Steam reforming is endothermic—that is, heat must be supplied to the process for the reaction to proceed
Implementation Method 3
In what is called the 'water-gas shift reaction,' the carbon monoxide and steam are reacted using another catalyst to produce carbon dioxide and more hydrogen
Implementation Method 4
hydrogen gas must be compressed to a high pressure (typically around 10,000 psi)
Implementation Method 5
utilizing waste heat from combustion cylinders to efficiently produce and compress hydrogen
Data Source
AI summary
An integrated hydrogen generator and compressor (200) that includes a combined engine compressor (collectively 109, 110, 111) and steam-methane reformer (104) to produce high-pressure hydrogen from natural gas (methane). The reformer (104) combines methane, water, and heat under high pressure in the presence of an appropriate catalyst, to produce hydrogen utilizing waste heat from combustion cylinders of the combined engine compressor (collectively 109, 110, 111). Compression serves to pressurize two different gases (methane and hydrogen) in different compression cylinders including the compression cylinders (109a, 109b, 109c) of the combined engine compressor (collectively 109, 110, 111) alternatively and/or optionally combined with internal combustion engine (310) and/or gas compressor(s) (410) that are integrated thermally and via communication of compressed gases.