Structured Catalyst Pre-Reforming for SOFC Coking Prevention
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Solution Overview
Problem
Current catalyst systems for pre-reforming hydrocarbons in solid oxide fuel cells face challenges such as coking, reduced catalyst lifespan, and inefficient conversion of heavier hydrocarbons to lighter hydrocarbons, leading to performance and cost issues.
Innovation Solution
A process utilizing a structured catalyst with a monolithic substrate coated with cerium-gadolinium oxide as a pre-coating layer and nickel-cerium-gadolinium oxide or nickel-ruthenium as an active catalyst layer, applied in multiple layers to enhance adhesion and stability, is used for pre-reforming hydrocarbons like diesel and natural gas, minimizing coke formation and extending catalyst life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unstructured particulate catalysts are used for pre-reforming, then catalyst activity can be achieved, but pressure drop control is poor and hot spot formation occurs
Solution Approach 1:
The patent applies a thin film catalyst coating on a structured support substrate, creating a structured catalyst that provides better pressure drop control and prevents hot spot formation compared to unstructured particulate catalysts, while maintaining catalytic activity
Solution Approach 2:
The patent creates a composite catalyst system by combining catalytic materials with a structured support substrate, forming a composite structured catalyst that integrates the benefits of both the catalytic activity of the particulate material and the structural advantages of the support for improved pressure drop control and thermal management
2Adaptability or versatility
If heavier hydrocarbons are fed to SOFC without pre-reforming, then fuel flexibility is improved, but coking occurs on the anode
Solution Approach 1:
The patent implements pre-reforming as a preliminary step before the hydrocarbons reach the SOFC anode, converting heavier hydrocarbons to lighter hydrocarbons, hydrogen, and carbon monoxide in advance to prevent coking on the anode while maintaining fuel flexibility
Solution Approach 2:
The structured catalyst acts as an intermediary between the heavier hydrocarbon fuel and the SOFC anode, facilitating the pre-reforming reaction to convert the fuel into a form suitable for anode processing, thereby preventing direct contact between heavy hydrocarbons and the anode surface that would cause coking
3Ease of manufacture
If conventional catalyst coating methods are used, then catalyst application is simple, but catalyst lifetime is reduced due to carbon deposition and sulfur poisoning
Solution Approach 1:
The patent applies a dual-layer coating structure where the first layer provides a specific function (e.g., thermal stability or resistance to carbon deposition) and the second layer contains the active catalytic components, creating local quality differences that enhance overall catalyst lifetime while maintaining ease of manufacture through sequential coating processes
Solution Approach 2:
The first catalyst layer acts as a protective barrier or cushioning layer applied beforehand to protect the active catalytic second layer from carbon deposition and sulfur poisoning, thereby extending catalyst lifetime while maintaining a relatively simple two-step coating manufacturing process
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 structured catalyst system effectively converts heavier hydrocarbons to hydrogen and methane, reducing coke formation, increasing catalyst longevity, and achieving higher reaction efficiency with lower catalyst consumption, thus improving the operational stability and cost-effectiveness of solid oxide fuel cells.
Implementation Method 1
pre-reforming, in the catalytic pre-reformer, the hydrocarbon fuel to produce a reformate exit stream including hydrogen and methane, wherein the catalytic pre-reformer includes a structured catalyst having a structured catalyst substrate, wherein the structured catalyst substrate is a monolithic structured catalyst substrate, a first coating containing cerium gadolinium oxide, the first coating being a pre-coating layer and being applied to a surface of the structured catalyst substrate; and a second coating containing nickel and cerium-gadolinium oxide, the second coating being an active catalyst layer and being applied to the first coating
Data Source
Figure 1A~1B
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AI summary
Provided herein are structured catalysts, methods of making structured catalysts, and methods of using structured catalysts for pre-reforming of hydrocarbons. The structured catalysts contain a structured catalyst substrate, a first coating containing cerium-gadolinium oxide; and a second coating containing nickel and cerium-gadolinium oxide.