Integrated Micro-channel Reformer with Concentric Tubes
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Solution Overview
Problem
Current systems for producing ultra-pure hydrogen from hydrocarbons involve separate reaction chambers and hydrogen separators, leading to inefficiencies and high costs, as they require two distinct components for the steam reforming and water gas shift reactions.
Innovation Solution
A single integrated component with concentric hydrogen permeable and impermeable tubes, where a gap between the tubes is heated to induce a water gas shift reaction, allowing hydrogen to permeate through the permeable tube for separation, thus acting as both a reactor and separator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate reaction chambers and hydrogen separators are used, then the steam reforming and water gas shift reactions can be performed, but the system complexity and cost increase
Solution Approach 1:
The patent combines the reaction chamber and hydrogen separator into a single integrated unit. The reaction chamber performs steam reforming and water gas shift reactions, while the hydrogen separator with permeable membrane separates hydrogen from the reaction gases. This merging eliminates the need for separate chambers and reduces system complexity while maintaining hydrogen production capability.
Solution Approach 2:
The integrated unit serves multiple functions simultaneously: it acts as a reaction chamber for chemical reactions, a separator for hydrogen purification, and a heat transfer medium conduit. This multi-functionality reduces the number of components needed and simplifies the overall system architecture.
2Reliability
If separate reactors and separators are used, then the hydrogen production process can be completed, but the energy consumption and cost increase
Solution Approach 1:
The integrated design allows continuous hydrogen production and separation within a single unit. The reaction gases flow directly from the reaction chamber into the hydrogen separator portion, eliminating intermediate transfer steps and maintaining continuous operation, which reduces energy consumption compared to separate units requiring intermediate handling.
Solution Approach 2:
The system uses the heat from the exothermic water gas shift reaction to maintain the temperature needed for the endothermic steam reforming reaction. This internal heat recycling reduces external energy input requirements while maintaining the necessary reaction conditions for hydrogen production.
3Device complexity
If integrated component is used, then the cost and energy consumption are reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent employs a nested tube structure where an inner reaction chamber tube is positioned concentrically within an outer separator tube. This nested configuration naturally maintains alignment and spacing through the concentric geometry, simplifying manufacturing compared to attempting to assemble separate aligned components. The nested design inherently provides structural support and alignment guidance.
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 integrated design efficiently produces and separates hydrogen, reducing costs and energy consumption by eliminating the need for separate reactors and separators, while maintaining high purity levels suitable for PEM fuel cells and other industrial applications.
Implementation Method 1
The purified hydrogen can then be used to power a fuel cell or serve some other industrial purpose. A single integrated component with concentric hydrogen permeable and impermeable tubes
Implementation Method 2
In this temperature range, a water gas shift reaction is induced. Once the water gas shift reaction is induced, the CO present in the resultant gases reacts with the water (H2O). The CO and the H2O react as follows: CO+H2O→CO2+H2
Implementation Method 3
In the steam reforming process the hydrocarbon fuel and water are converted in an endothermic reaction principally into hydrogen (H2), carbon monoxide (CO), methane (CH4), carbon dioxide (CO2) and water (H2O)
Data Source
AI summary
A system and method of producing hydrogen from a mixture of hydrocarbon fuel and steam. Reaction cells are provided that each contains a first tube of hydrogen permeable material and a second tube of hydrogen impermeable material that are concentrically positioned. This creates a gap space between the first tube and the second tube. The gap space is heated by burning a combustion gas outside of the two concentric tubes. A water gas shift reaction occurs in the gap space. Hydrogen is created that permeates through the first tube and becomes separated from the remainder of the reaction gases. The hydrogen gas is collected for use. As such, the system and method acts both as a gas shift reactor and as a hydrogen separator even though it is a single unit.