Fuel reformer system

• US 20020108309A1
• Filed: 02/13/2001
• Published: 08/15/2002
• Est. Priority Date: 02/13/2001
• Status: Active Grant

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Hendler, Peter, Grieve, M. James, Haltiner, Karl Jr., Noetzel, John
• Granted Patent: US 7,160,342 B2
• Time in Patent Office: Days
• US Class Current: 48/197R
• CPC Class Codes: B01J 19/0093 Microreactors, e.g. miniaturised or microfabricated reactors laboratory containers with capillary fluid transport in microfabricated channels or chambers B01L3/5027
• CPC Class Codes: B01J 2208/00061 of the reactants
• CPC Class Codes: B01J 2208/00309 with two or more reactions in heat exchange with each other, such as an endothermic reaction in heat exchange with an exothermic reaction
• CPC Class Codes: B01J 2208/00415 electric resistance heaters
• CPC Class Codes: B01J 2208/0053 Controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
• CPC Class Codes: B01J 2208/00716 Means for reactor start-up
• CPC Class Codes: B01J 2219/00063 of the reactants
• CPC Class Codes: B01J 2219/00191 Control algorithm
• CPC Class Codes: B01J 2219/00193 Sensing a parameter
• CPC Class Codes: B01J 2219/00835 Comprising catalytically active material
• CPC Class Codes: B01J 2219/00873 Heat exchange
• CPC Class Codes: B01J 2219/00891 Feeding or evacuation
• CPC Class Codes: B01J 8/0442 the beds being placed in separate reactors
• CPC Class Codes: B01J 8/0492 Feeding reactive fluids for solid material, see B01J8/0015
• CPC Class Codes: B60L 58/31 for starting of fuel cells
• CPC Class Codes: B60L 58/34 by heating
• CPC Class Codes: C01B 2203/141 At least two reforming, decomposition or partial oxidation steps in parallel
• CPC Class Codes: C01B 3/323 Catalytic reaction of gaseous or liquid organic compounds other than hydrocarbons with gasifying agents
• CPC Class Codes: C01B 3/382 Multi-step processes
• CPC Class Codes: H01M 8/0612 from carbon-containing material
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02T 10/92 : Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A method of main reformer startup is disclosed. The method comprises introducing a first supply of fuel and a first supply of air into a micro-reformer. The first supply of fuel is increased to produce a heated reformate in the micro-reformer. The heated reformate is directed through a main reformer in order to heat the main reformer. At least a portion of the heated reformate is burned in the main reformer. A second supply of fuel and a second supply of air is introduced into the main reformer to produce a main supply of reformate. A method for maintaining a vehicle device in standby condition is also disclosed.

Claims

1. A method of main reformer startup, comprising:

introducing a first supply of fuel and a first supply of air into a micro-reformer;

increasing said first supply of fuel to produce a heated reformate in said micro-reformer;

directing said heated reformate through a main reformer to heat said main reformer;

burning at least a portion of said heated reformate in said main reformer; and

introducing a second supply of fuel and a second supply of air to said main reformer to produce a main supply of reformate.

2. The method of claim 1, further comprising electrically pre-heating said micro-reformer.

3. The method of claim 2, wherein said micro-reformer has an inlet air temperature at about 140°

C. or greater and a catalyst exit temperature of about 300°

C. or greater.

4. The method of claim 1, wherein said micro-reformer has a catalyst volume of about 50% or less of a catalyst volume of said main reformer.

5. The method of claim 1, wherein said main reformer consists essentially of a catalyst and ceramic components.

6. The method of claim 1, wherein said first supply of fuel has an equivalence ratio of about 0.4 to about 0.7.

7. The method of claim 1, wherein said increasing said first supply of fuel is to an equivalence ratio of about 2.7 to about 2.9.

8. The method of claim 7, wherein said micro-reformer has a catalyst exit temperature of about 500°

C. or greater.

9. The method of claim 1, wherein said second supply of fuel has an equivalence ratio of about 1.8 to about 2.2.

10. The method of claim 9, wherein said main reformer has catalyst exit temperature at about 500°

C. or greater.

11. The method of claim 1, further comprising electrically preheating said micro-reformer.

12. The method of claim 1, wherein said micro-reformer has a catalyst volume equal to about 50% or less of a catalyst volume of said main reformer.

13. The method of claim 12, wherein said micro-reformer has a catalyst volume equal to about 35% or less of a catalyst volume of said main reformer.

14. The method of claim 12, wherein said micro-reformer has a catalyst volume equal to about 25% to about 10% of a catalyst volume of said main reformer.

16. The method of claim 15, further comprising electrically pre-heating said micro-reformer.

17. The method of claim 16, wherein said micro-reformer has an inlet air temperature at about 140°

C. or greater and a catalyst exit temperature of about 300°

C. or greater.

18. The method of claim 15, further comprising burning at least a portion of said heated reformate in said vehicle device.

19. The method of claim 15, wherein said vehicle device is a device selected from the group consisting of a reformer, a waste energy recovery burner device, a catalytic after treatment system, a burner, a fuel fired heater device, and combinations comprising at least one of the foregoing devices.

20. The system of claim 15, wherein said standby temperature is about 200°

C. to about 400°

C.

21. The system of claim 20, wherein said standby temperature is about 250°

C. to about 300°

C.

22. The method of claim 15, wherein said first supply of fuel has an equivalence ratio of about 0.4 to about 0.7.

23. The method of claim 15, wherein said increasing said first supply of fuel is to an equivalence ratio of about 2.7 to about 2.9.

24. The method of claim 23, wherein said micro-reformer has a catalyst exit temperature of about 500°

C. or greater.

15. A method for maintaining a vehicle device in standby condition, comprising:

introducing a supply of fuel and a supply of air into a micro-reformer;

increasing said supply of fuel to produce a heated reformate in said micro-reformer;

passing at least a portion of said heated reformate through said vehicle device; and

maintaining said vehicle device at a standby temperature.