Monolithic Fuel Processor Integrating Burner and Reformer
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Solution Overview
Problem
Fuel cell systems face inefficiencies due to thermal inefficiencies, which lead to energy wastage and the need for more fuel consumption, primarily because existing fuel processors are not designed to maintain controlled temperatures, resulting in hot and cold spots that hinder hydrogen production from hydrocarbon fuels.
Innovation Solution
A fuel processor with a monolithic structure that aligns the fluid flow directions in the burner and reformer chambers to prevent hot and cold spots, utilizing a regenerator to pre-heat air and a recuperator to manage heat, ensuring efficient hydrogen production and catalyst integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuel processors are designed specifically for a given fuel cell stack, then the fuel cell system can achieve power performance and hydrogen fuel consumption requirements, but the system volume and mass increase due to substantial fluidic and gaseous manifolding and thermal insulation
Solution Approach 1:
The fuel processor is integrated directly with the fuel cell stack, merging previously separate components into a unified structure. This eliminates the need for separate fluidic and gaseous manifolding systems and reduces thermal insulation requirements, thereby decreasing system volume and mass while maintaining power performance
Solution Approach 2:
The integrated fuel processor-fuel cell stack design creates a multi-functional unit that performs both fuel processing and power generation functions. This universal design allows the same structure to serve multiple purposes, reducing the overall system complexity and volume
2Temperature
If a separate device such as a stack burner is used to assist the fuel cell stack in achieving operation temperatures, then the fuel cell can reach operating temperature, but thermal inefficiencies occur leading to energy wastage and increased fuel consumption
Solution Approach 1:
The fuel processor and fuel cell stack are merged into an integrated unit, allowing direct thermal coupling between the fuel processing reactions and the fuel cell operation. This eliminates the need for separate heating devices and reduces thermal losses by maintaining controlled temperatures through the integrated design
Solution Approach 2:
The integrated design enables continuous useful action by allowing the fuel processing reactions to continuously provide heat to the fuel cell stack, maintaining operating temperature without interruption or energy wastage associated with separate heating cycles
3Ease of operation
If fuel processors operate without controlled temperatures, then the system is simpler to operate, but hot and cold spots occur that hinder hydrogen production and catalyst integrity
Solution Approach 1:
The integration of the fuel processor with the fuel cell stack creates a unified thermal management system that automatically maintains controlled temperatures through the coupled reactions, eliminating the need for complex external temperature control mechanisms while ensuring uniform temperature distribution for optimal hydrogen production
Solution Approach 2:
The integrated design changes the thermal parameters of the system by allowing direct heat transfer between the fuel processing exothermic reactions and the fuel cell endothermic reactions, maintaining controlled temperatures that optimize hydrogen production efficiency and catalyst integrity
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 design enhances the fuel processor's performance by maintaining controlled temperatures, reducing energy wastage, and improving hydrogen production efficiency, thereby optimizing the fuel cell system's energy output.
Implementation Method 1
a regenerator having a first inlet to receive an air flow, a burner flow chamber within the regenerator, the burner flow chamber having a second inlet to receive the air flow from the regenerator
Implementation Method 2
a burner flow chamber within the regenerator, the burner flow chamber having a second inlet to receive the air flow from the regenerator
Implementation Method 3
a reformer flow chamber positioned between the regenerator and the burner flow chamber, the reformer flow chamber having a third inlet to receive the air flow from the burner chamber
Data Source
AI summary
In one embodiment, a fuel processor for use in a fuel cell system, may have a bottom plate, having a regenerator having a first inlet to receive an air flow, a burner flow chamber within the regenerator, the burner flow chamber having a second inlet to receive the air flow from the regenerator, and a reformer flow chamber positioned between the regenerator and the burner flow chamber, the reformer flow chamber having a third inlet to receive the air flow from the burner chamber, wherein the burner flow chamber and the reformer flow chamber is formed of a monolithic structure having an elongated, rounded baffle in the center of the monolithic structure. The fuel processor may also have a top plate coupled to the bottom plate to enclose the fuel processor, the top plate having a top surface and a bottom surface.