Startup Burner Two-Zone Combustion Rapid Catalyst Heating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Compact fuel reformers face challenges in rapid startup due to the time required to heat the catalyst to the desired light-off temperature, which hinders efficient automotive use.

Innovation Solution

A startup burner system that mixes a rich fuel/air mixture, ignites it, and then reacts it with a second oxygenated flow to produce a final gas for heating the catalyst, achieving the light-off temperature in three minutes or less, with a modular design allowing for efficient heat transfer and lean combustion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a compact fuel reformer design is used, then energy density is improved, but startup time increases due to slow catalyst heating

Engineering Contradiction:

Improveenergy densityVSAvoidstartup time

Core Design Contradiction:

Use of energy by moving objectVSLoss of time

Solution Approach 1:

The catalyst heating process is segmented into two distinct zones: a first mixing zone where fuel and first oxygenated flow are mixed and ignited, and a second mixing zone where the partially oxidized mixture reacts with a second oxygenated flow. This segmentation allows independent optimization of each zone's function, enabling rapid heating while maintaining compact overall design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the reformer are given different functional qualities: the first mixing zone is designed for rich combustion to generate high temperatures, while the second mixing zone is designed for lean combustion to control exhaust temperature. This local differentiation enables the catalyst to be heated rapidly without requiring the entire reformer to be oversized.

Inventive Principle:

Principle #3Local quality

2Loss of time

If rapid catalyst heating is implemented, then startup time is reduced, but temperature control becomes more challenging

Engineering Contradiction:

Improvestartup timeVSAvoidtemperature control

Core Design Contradiction:

Loss of timeVSTemperature

Solution Approach 1:

The system changes the oxygen-to-fuel ratio parameter between two distinct zones: a rich mixture in the first mixing zone for rapid heating, and a lean mixture in the second mixing zone for temperature control. This parameter variation enables both rapid startup and controlled exhaust temperature to be achieved simultaneously.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The partially oxidized mixture from the first mixing zone serves as an intermediary that transfers thermal energy to the second mixing zone. This intermediary allows the heat generated in the rich combustion zone to be utilized in the lean combustion zone, enabling temperature control while maintaining rapid heating capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If a two-zone combustion system is used, then heating efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveheating efficiencyVSAvoidburner structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The two mixing zones are merged into a single integrated burner assembly that can be removably detached from the reformer. This merging reduces the number of separate components compared to having two independent heating systems, while still achieving the heating efficiency benefits of two-zone combustion.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The startup burner assembly serves multiple functions: it provides rapid catalyst heating, controls exhaust temperature, and can be removably detached for maintenance or replacement. This multi-functionality reduces the need for separate dedicated systems for each function, thereby reducing overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system significantly reduces catalyst heating time, enabling quicker startup of fuel reformers and maintaining efficiency in both startup and normal operation phases, with direct heat transfer to the catalyst and controlled exhaust temperature.

Implementation Method 1

igniting the rich fuel/air mixture to produce a partially oxidized mixture

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 2

reacting the partially oxidized mixture with a second oxygenated flow to produce a final gas

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 3

heating a reforming catalyst by flowing the final gas through the catalyst

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS7575614B2Startup burner

Publication Date: 2009.08.18 POWERTAP HYDROGEN FUELING CORP

AI summary

A startup burner for rapidly heating a catalyst in a reformer, as well as related methods and modules, is disclosed.