Fuel Cell Reformer Vaporization Acceleration via Porous Flow Control

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Solution Overview

Problem

Existing fuel cell reformers face inefficiencies in both vaporization and reforming reactions, particularly in steam-reforming processes, where efficient water vaporization and stable reforming reaction rates are crucial for consistent power generation.

Innovation Solution

The reformer design incorporates a vaporization portion with a water diffusion member, such as a metal net or ceramic fibers, and a reforming portion with partition walls to enhance heat transfer and vaporization efficiency, along with a dual or triple pipe structure for raw fuel and water introduction to manage flow and prevent instantaneous water influx, thereby stabilizing vaporization and reforming reactions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If water is introduced into the vaporization portion without flow suppression, then the vaporization portion can be simple in structure, but water may flow instantaneously causing unstable vaporization and reforming reactions

Engineering Contradiction:

Improvestability of vaporization and reforming reactionsVSAvoidcomplexity of water introduction system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a porous plug or porous plate in the water introduction pipe to suppress instantaneous water flow. The porous structure allows water to pass through while regulating its flow rate, preventing water hammer effects and ensuring stable vaporization. This resolves the contradiction by adding minimal structural complexity (a porous component) to achieve reliable stable operation.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent changes the flow parameters of water by introducing it through a porous structure rather than a direct opening. This parameter change (from unrestricted flow to controlled porous flow) stabilizes the vaporization process and reforming reactions while keeping the overall system relatively simple.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If a vaporization accelerating portion is added to enhance water vaporization, then vaporization efficiency improves, but device complexity increases

Engineering Contradiction:

Improveefficiency of water vaporizationVSAvoidcomplexity of reformer structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The vaporization accelerating portion utilizes porous plugs or porous plates that increase the surface area for water evaporation. The porous structure allows water to spread out and vaporize more efficiently while being heated by the reforming reaction. This achieves higher productivity in vaporization with relatively simple integration into the existing reformer structure.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The vaporization accelerating portion may use composite structures combining different materials (e.g., porous ceramic or metal materials) that provide both thermal resistance and high surface area for vaporization. This composite approach enhances vaporization efficiency while maintaining structural integrity and managing thermal loads.

Inventive Principle:

Principle #40Composite materials

3Productivity

If partition walls are added to the reforming portion to improve heat transfer, then reforming reaction efficiency increases, but device complexity increases

Engineering Contradiction:

Improveefficiency of reforming reactionVSAvoidcomplexity of reformer internal structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The reforming portion is divided into multiple chambers by partition walls, creating a segmented structure that improves heat transfer and controls the reforming reaction zones. Each chamber can be optimized for specific reaction conditions, enhancing overall reforming efficiency while maintaining a modular and manageable structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The partition walls create local zones with different thermal and chemical conditions within the reforming portion. This local quality variation allows different parts of the reformer to perform specialized functions (e.g., primary reforming, secondary reforming, heat exchange), improving overall reaction efficiency through functional differentiation.

Inventive Principle:

Principle #3Local quality

4Reliability

If a dual or triple pipe structure is used for raw fuel and water introduction, then flow control and prevention of instantaneous water influx is improved, but device complexity increases

Engineering Contradiction:

Improvecontrol of water and raw fuel flowVSAvoidcomplexity of introduction pipe structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The introduction system is segmented into separate pipes for raw fuel and water, with the water pipe further divided into sections (dual or triple structure) that include porous plugs or flow control elements. This segmentation allows independent control of each fluid's flow characteristics, preventing instantaneous water influx while maintaining manageable structural complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Porous plugs or flow control elements act as intermediaries in the water introduction path, mediating between the water source and the vaporization portion. These intermediary components regulate water flow to prevent instantaneous influx while allowing controlled vaporization, adding minimal complexity to achieve reliable flow control.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration improves the efficiency of water vaporization and reforming reactions, leading to stable power generation by ensuring consistent steam production and reforming gas flow, thus enhancing the overall performance of the fuel cell system.

Implementation Method 1

a vaporization portion which vaporizes water to generate steam

Methodology Applied

Scientific EffectVaporization: Evaporation

Implementation Method 2

a reforming portion which steam-reforms raw fuel (including gaseous raw fuel gas) by using the steam generated in the vaporization portion

Methodology Applied

Scientific EffectSteam-reforming reaction: Chemical Transport Reactions

Implementation Method 3

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS11189850B2Reformer, cell stack apparatus, fuel cell module, and fuel cell apparatus

Publication Date: 2021.11.30 KYOCERA CORP

AI summary

A reformer of the present disclosure includes a reformer body which has a cylindrical shape and extends horizontally, introducing raw fuel and water to perform a reforming reaction, the reformer body including therein a vaporization portion which generates steam, and a reforming portion which reacts the steam generated in the vaporization portion with raw fuel to generate a reformed gas; a raw fuel introduction pipe which introduces the raw fuel into the reformer body; a water introduction pipe including therein a water passage which introduces water into the reformer body; and a vaporization accelerating portion which is disposed in at least one of the vaporization portion and the water introduction pipe and accelerates vaporization of water in the vaporization portion.