Steam reforming fuel processor, burner assembly, and methods of operating the same

• US 20030223926A1
• Filed: 04/10/2003
• Published: 12/04/2003
• Est. Priority Date: 04/14/2002
• Status: Abandoned Application

• Current Assignee: IdaTech LLC (IdaTech Ltd.)
• Original Assignee: IdaTech LLC (IdaTech Ltd.)
• Inventors: Stephens, Redwood, Edlund, David J., Renn, Curtiss, Pledger, William A., Hayes, Alan E., Elliott, Darrell J., Studebaker, R. Todd
• Application Number:
  US10/412,709
• Publication Number:
  US 20030223926A1
• Time in Patent Office: Days
• US Class Current: 422/198
• CPC Class Codes: B01J 2208/00132 Tubes
• CPC Class Codes: B01J 2208/00141 Coils
• 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 2208/00504 by means of a burner
• 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 8/0221 in a cylindrical shaped bed B01J8/0214 takes precedence
• CPC Class Codes: B01J 8/0285 Heating or cooling the reactor for tubular reactors in furnaces B01J8/062
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/041 In-situ membrane purification during hydrogen production
• CPC Class Codes: C01B 2203/0465 Composition of the impurity
• CPC Class Codes: C01B 2203/047 the impurity being carbon monoxide
• CPC Class Codes: C01B 2203/0475 the impurity being carbon dioxide
• CPC Class Codes: C01B 2203/048 the impurity being an organic compound
• CPC Class Codes: C01B 2203/0485 the impurity being a sulfur compound
• CPC Class Codes: C01B 2203/0495 the impurity being water
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• CPC Class Codes: C01B 3/501 by diffusion
• CPC Class Codes: F23D 14/22 with separate air and gas feed ducts, e.g. with ducts running parallel or crossing each other
• CPC Class Codes: F23D 91/02 for use in particular heating operations
• CPC Class Codes: H01M 8/04022 : Heating by combustion
• CPC Class Codes: H01M 8/0612 : from carbon-containing material
• CPC Class Codes: H01M 8/0631 : Reactor construction specially adapted for combination reactor/fuel cell hydrogen C01B3/00; reactors for physicochemical processes B01J19/00
• CPC Class Codes: H01M 8/0668 : Removal of carbon monoxide or carbon dioxide
• CPC Class Codes: H01M 8/0687 : Reactant purification by the use of membranes or filters
• CPC Class Codes: Y02E 60/50 : Fuel cells

Abstract

Diffusion and atomizing burner assemblies and fuel processing and fuel cell systems containing the same. The burner assembly receives at least one liquid and/or gaseous fuel stream, mixes the stream with air, and combusts the mixed stream to provide heat for a fuel processor. In some embodiments, the burner assembly receives at least one combustible fuel stream produced by the fuel processing and/or fuel cell system. In some embodiments, the burner assembly receives a fuel stream having the same composition as a stream that is delivered for non-combustion purposes to another portion of the fuel processing and/or fuel cell system. In some embodiments, the burner assembly receives and vaporizes a fuel stream that includes the same carbon-containing feedstock and/or has the same overall composition as the feed stream from which the steam reformer or other fuel processor produces hydrogen gas. Methods of use are also disclosed.

Claims

1. A steam reforming fuel processor, comprising:

a reforming region containing a reforming catalyst, wherein the reforming region is adapted to receive a feed stream comprising water and a carbon-containing feedstock and to produce a mixed gas stream containing hydrogen gas and other gases therefrom;

a burner assembly adapted to receive an air stream and a combustible fuel stream and to produce a combustion stream for heating at least the reforming region of the fuel processor;

wherein the feed stream and the fuel stream both comprise a carbon-containing feedstock and at least 25% water.

2. The fuel processor of claim 1, wherein at least one of the feed stream and the fuel stream further comprise at least one additional component.

3. The fuel processor of claim 1, wherein the feed stream and the fuel stream have the same composition.

4. The fuel processor of claim 1, wherein the fuel processor further includes a valve assembly that is adapted to receive a stream containing water and a liquid carbon-containing feedstock and to apportion the ed stream into feed stream for the reforming region and the combustible fuel stream for the burner assembly.

5. The fuel processor of claim 1, wherein the fuel processor further includes at least one separation region adapted to receive at least a portion of the mixed gas stream and to produce therefrom a hydrogen-rich stream containing at least substantially pure hydrogen gas and a byproduct stream containing at least a substantial portion of the other gases.

6. The fuel processor of claim 5, wherein the burner assembly is further adapted to receive at least a portion of the byproduct stream as a gaseous combustible fuel stream.

7. The fuel processor of claim 5, wherein the at least one separation region includes at least one hydrogen-selective membrane.

8. The fuel processor of claim 5, wherein the at least one separation region includes at least one carbon monoxide removal assembly adapted to reduce the concentration of any carbon monoxide present in the mixed gas stream.

9. The fuel processor of claim 1, wherein the burner assembly is adapted to receive a liquid combustible fuel stream, and further wherein the burner assembly includes an atomization assembly that is adapted to receive and atomize the liquid combustible fuel stream.

10. The fuel processor of claim 1, wherein the burner assembly is adapted to receive a liquid combustible fuel stream, and further wherein the burner assembly includes a vaporization region that is adapted to receive and vaporize the liquid combustible fuel stream to form a vaporized fuel stream therefrom.

11. The fuel processor of claim 10, wherein the burner assembly further includes a diffusion region adapted to receive and mix the vaporized fuel stream and the air stream to form an oxygenated combustible fuel stream.

12. A fuel processor, comprising:

a hydrogen-producing region adapted to receive a feed stream and to produce a mixed gas stream containing hydrogen gas and other gases therefrom;

a burner assembly adapted to produce a heated exhaust stream for heating at least the hydrogen-producing region of the fuel processor, wherein the burner assembly is adapted to receive a combustible fuel stream and an air stream and to combust the fuel and air streams to produce the heated exhaust stream; and

means for controlling the amount of heat produced by the burner assembly by controlling the rate at which the air stream is delivered to the burner assembly.

13. The fuel processor of claim 12, wherein the fuel stream and the feed stream share a common carbon-containing feedstock component.

14. The fuel processor of claim 12, wherein the fuel stream and the feed stream have the same composition.

15. The fuel processor of claim 12, wherein the fuel stream and the feed stream contain at least 25% water.

16. The fuel processor of claim 12, wherein the hydrogen-producing region includes at least one reforming catalyst bed containing a steam reforming catalyst, and further wherein the feed stream comprises water and a carbon-containing feedstock.

17. The fuel processor of claim 12, wherein the fuel processor further includes at least one separation region adapted to receive at least a portion of the mixed gas stream and to produce a hydrogen-rich stream containing at least substantially pure hydrogen gas and at least one byproduct stream containing at least a substantial portion of the other gases.

18. The fuel processor of claim 17, wherein the at least one separation region includes at least one hydrogen-selective membrane.

19. The fuel processor of claim 17, wherein the at least one separation region includes a membrane module that contains a compartment into which the mixed gas stream is delivered under pressure, and further wherein the compartment contains at least one hydrogen-selective membrane, the hydrogen-rich stream is formed from a portion of the mixed gas stream that passes through the at least one hydrogen-selective membrane, and the byproduct stream is formed form a portion of the mixed gas stream that does not pass through the at least one membrane.

20. The fuel processor of claim 19, wherein the at least one separation region further includes at least one carbon monoxide removal assembly adapted to reduce the concentration of any carbon monoxide present in the hydrogen-rich stream.

21. The fuel processor of claim 12, wherein the burner assembly is adapted to selectively receive both liquid and gaseous combustible fuel streams.

22. The fuel processor of claim 12, wherein the burner assembly is adapted to receive a liquid combustible fuel stream, and further wherein the burner assembly includes an atomization assembly that is adapted to receive and atomize the liquid combustible fuel stream.

23. The fuel processor of claim 12, wherein the burner assembly is adapted to receive a liquid combustible fuel stream, and further wherein the burner assembly includes a vaporization region that is adapted to receive and vaporize the liquid combustible fuel stream to form a vaporized fuel stream therefrom.

24. The fuel processor of claim 23, wherein the burner assembly further includes a diffusion region adapted to receive and mix the vaporized fuel stream and the air stream to form an oxygenated combustible fuel stream.

25. A fuel processor, comprising:

a hydrogen-producing region adapted to receive a feed stream and to produce a mixed gas stream containing hydrogen gas and other gases therefrom;

at least one separation region adapted to receive at least a portion of the mixed gas stream and to produce a hydrogen-rich stream containing at least substantially pure hydrogen gas and at least one byproduct stream containing at least a substantial portion of the other gases;

a diffusion burner assembly adapted to produce a heated exhaust stream for heating at least the hydrogen-producing region of the fuel processor, wherein the diffusion burner assembly is adapted to receive an air stream and a combustible fuel stream, wherein the diffusion burner assembly comprises;

a diffusion region adapted to mix the combustible fuel stream and the air stream to form an oxygenated combustible fuel stream; and

a combustion region adapted to receive the oxygenated combustible fuel stream; and

at least one ignition region adapted to initiate combustion of the oxygenated combustible fuel stream.

26. The fuel processor of claim 25, wherein the distribution region includes a diffusion structure adapted to promote the formation of a plurality of oxygenated combustible fuel streams.

27. The fuel processor of claim 26, wherein the diffusion structure is adapted to divide the air stream into a plurality of air streams and to divide the combustible fuel stream into a plurality of combustible fuel streams.

28. The fuel processor of claim 27, wherein each of the plurality of air streams contains no more than 10% of the air stream.

29. The fuel processor of claim 27, wherein each of the plurality of combustible fuel streams contains no more than 10% of the combustible fuel stream.

30. The fuel processor of claim 27, wherein the diffusion structure includes a fuel distribution manifold containing a plurality of fuel apertures into which the combustible fuel stream is divided into the plurality of combustible fuel streams, and further wherein the plurality of fuel apertures are in communication with a plurality of fuel tubes having fuel outlets adapted to deliver the plurality of fuel streams to the combustion region.

31. The fuel processor of claim 30, wherein the diffusion region further includes an air distribution chamber.

32. The fuel processor of claim 31, wherein the air distribution chamber is adapted to receive the air stream and permit the air stream to flow around the plurality of fuel tubes.

33. The fuel processor of claim 32, wherein the diffusion region includes a combustion manifold separating the air diffusion chamber and the combustion region, wherein the combustion manifold includes a plurality of apertures through which the air stream is divided into the plurality of air streams, and further wherein each of the fuel outlets of the plurality of fuel tubes is associated with one of the plurality of apertures.

34. The fuel processor of claim 33, wherein each fuel outlet extends at least partially through one of the plurality of apertures.

35. The fuel processor of claim 33, wherein each fuel outlet extends through one of the plurality of apertures.

36. The fuel processor of claim 33, wherein the combustion manifold is adapted to maintain the air distribution chamber at a pressure that is greater than the pressure within the combustion region.

37. The fuel processor of claim 33, wherein the diffusion burner assembly is adapted to receive a combustible fuel stream in the form of a liquid combustible fuel stream, and further wherein the diffusion burner assembly includes a vaporization region that is adapted to vaporize the liquid combustible fuel stream.

38. The fuel processor of claim 37, wherein the vaporization region includes at least one reservoir adapted to receive a volume of the liquid combustible fuel stream.

39. The fuel processor of claim 37, wherein the fuel distribution manifold is adapted to maintain the vaporization region at a pressure that is greater than the pressure in the plurality of fuel tubes.

40. The fuel processor of claim 33, wherein the diffusion burner assembly is adapted to receive a combustible fuel stream in the form of a gaseous combustible fuel stream.

41. The fuel processor of claim 40, wherein the gaseous combustible fuel stream includes at least a portion of the byproduct stream.

42. The fuel processor of claim 25, wherein a stream that contains a carbon-containing feedstock is delivered to the fuel processor as a single stream and thereafter divided into a stream that forms at least a portion of the feed stream and a stream that forms at least a portion of the fuel stream.

43. The fuel processor of claim 25, wherein the fuel stream and the feed stream both contain water and a carbon-containing feedstock.

44. The fuel processor of claim 43, wherein the fuel stream and the feed stream both contain at least 25 wt % water and a carbon-containing feedstock.

45. The fuel processor of claim 25, wherein the fuel stream and the feed stream have the same composition.

46. The fuel processor of claim 25, wherein at least one of the fuel stream and the feed stream further comprise at least one additional component.

47. The fuel processor of claim 25, wherein the fuel processor is adapted to produce the mixed gas stream via a steam reforming reaction, wherein the hydrogen-producing region includes at least one reforming region that contains a reforming catalyst, and further wherein the feed stream contains water and a carbon-containing feedstock.

48. The fuel processor of claim 47, wherein the feed stream is delivered to the fuel processor as an at least substantially liquid stream and divided into the feed stream for the hydrogen-producing region of the fuel processor and the fuel stream for the burner assembly.

49. The fuel processor of claim 48, wherein the fuel processor includes a vaporization region in which the feed stream is vaporized at least partially responsive to thermal contact with the heated exhaust stream from the burner assembly.

50. The fuel processor of claim 25, wherein the burner assembly is further adapted to receive a gaseous fuel stream.

51. The fuel processor of claim 25, wherein the burner assembly is further adapted to receive at least a portion of the byproduct stream as a gaseous fuel stream.

52. A fuel processor, comprising:

a hydrogen-producing region adapted to receive a feed stream and to produce a mixed gas stream containing hydrogen gas and other gases therefrom;

at least one separation region adapted to receive at least a portion of the mixed gas stream and to produce a hydrogen-rich stream containing at least substantially pure hydrogen gas and at least one byproduct stream containing at least a substantial portion of the other gases; and

an atomizing burner assembly adapted to produce a heated exhaust stream for heating at least the hydrogen-producing region of the fuel processor, wherein the atomizing burner assembly is adapted to receive an air stream and to receive under pressure a liquid combustible fuel stream, and further wherein the atomizing burner assembly comprises;

an atomization assembly adapted to receive the liquid combustible fuel stream and to produce an atomized fuel stream therefrom; and

an ignition region with at least one ignition source adapted to initiate combustion of the atomized fuel stream and the air stream.

53. The fuel processor of claim 52, wherein the liquid combustible fuel stream is delivered to the fuel atomization assembly at a pressure of at least 50 psi.

54. The fuel processor of claim 52, wherein the atomization assembly includes an atomization orifice adapted to produce the atomized fuel stream from the liquid combustible fuel stream as the liquid combustible fuel stream passes through the orifice.

55. The fuel processor of claim 52, wherein the atomization assembly includes at least one impingement surface adapted to produce the atomized fuel stream as the liquid combustible fuel stream is urged under pressure into contact with the impingement surface.

56. The fuel processor of claim 52, wherein the atomizing burner assembly is adapted to promote mixing of the atomized fuel stream and the air stream prior to combustion of the atomized fuel stream.

57. The fuel processor of claim 52, wherein the ignition region includes a constricted outlet through which the heated exhaust stream exits the ignition region, and further wherein the outlet is adapted to promote greater mixing of the atomized fuel stream and the air stream.

58. The fuel processor of claim 52, wherein the atomizing burner assembly includes a distribution plate adapted to promote turbulent mixing of the atomized fuel stream and the air stream.

59. The fuel processor of claim 58, wherein the distribution plate includes a plurality of angularly oriented passages through which the air stream and the atomized fuel stream pass prior to reaching the ignition region.

60. The fuel processor of claim 52, wherein a stream that contains a carbon-containing feedstock is delivered to the fuel processor as a single stream and thereafter divided into a stream that forms at least a portion of the feed stream and a stream that forms at least a portion of the fuel stream.

61. The fuel processor of claim 52, wherein the fuel stream and the feed stream both contain water and a carbon-containing feedstock.

62. The fuel processor of claim 61, wherein the fuel stream and the feed stream both contain at least 25 wt % water and a carbon-containing feedstock.

63. The fuel processor of claim 52, wherein the fuel stream and the feed stream have the same composition.

64. The fuel processor of claim 52, wherein at least one of the fuel stream and the feed stream further comprise at least one additional component.

65. The fuel processor of claim 52, wherein the fuel processor is adapted to produce the mixed gas stream via a steam reforming reaction, with the fuel processor including at least one reforming region that contains a reforming catalyst, and further wherein the feed stream contains water and a carbon-containing feedstock.

66. The fuel processor of claim 65, wherein the feed stream is delivered to the fuel processor as an at least substantially liquid stream and divided into the feed stream for the hydrogen-producing region of the fuel processor and the fuel stream for the burner assembly.

67. The fuel processor of claim 66, wherein the fuel processor includes a vaporization region in which the feed stream is vaporized at least partially responsive to thermal contact with the heated exhaust stream from the burner assembly.

68. The fuel processor of claim 52, wherein the burner assembly is further adapted to receive a gaseous fuel stream.

69. The fuel processor of claim 52, wherein the burner assembly is further adapted to receive at least a portion of the byproduct stream as a gaseous fuel stream.