Methods of using integrated fuel processor apparatus and enclosure

• US 20060219643A1
• Filed: 06/02/2006
• Published: 10/05/2006
• Est. Priority Date: 04/04/2003
• Status: Active Grant

• Current Assignee: Texaco Incorporated (Chevron Corp.)
• Original Assignee: Texaco Incorporated (Chevron Corp.)
• Inventors: Wheat, William Spencer, Worsley, Ralph Stanley, Bunk, Kenneth Joseph
• Granted Patent: US 7,858,245 B2
• Time in Patent Office: Days
• US Class Current: 210/767
• CPC Class Codes: B01J 8/02 with stationary particles, e.g. in fixed beds
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/0244 the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• CPC Class Codes: C01B 2203/0283 containing a CO-shift step, i.e. a water gas shift step
• CPC Class Codes: C01B 2203/04 containing a purification step for the hydrogen or the synthesis gas
• CPC Class Codes: C01B 2203/042 Purification by adsorption on solids
• CPC Class Codes: C01B 2203/045 Purification by catalytic desulfurisation
• 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 2203/066 with fuel cells
• CPC Class Codes: C01B 2203/0877 by direct injection of fluid
• CPC Class Codes: C01B 3/38 using catalysts
• CPC Class Codes: C01B 3/48 followed by reaction of water vapour with carbon monoxide
• CPC Class Codes: H01M 8/04164 by condensers, gas-liquid separators or filters
• CPC Class Codes: H01M 8/0618 Reforming processes, e.g. autothermal, partial oxidation or steam reforming
• CPC Class Codes: H01M 8/0668 Removal of carbon monoxide or carbon dioxide
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 29/49345 Catalytic device making
• CPC Class Codes: Y10T 29/49428 Gas and water specific plumbing component making

Abstract

An integrated fuel processor apparatus and enclosure for converting hydrocarbon fuel to a hydrogen rich gas. The integrated apparatus includes a fuel processor for producing a hydrogen-rich reformate that contains water and a combustible gas component. The fuel processor is enclosed in a gas impermeable enclosure that has a collection vessel for receiving water separated from the reformate stream. The collection vessel has a drain for directing the water out of the enclosure. The collection vessel is open to the interior of the enclosure so that combustible gases that are entrained in the water can evaporate to the interior of the enclosure. The enclosure has a ventilator for evacuating the combustible gases from within the enclosure. Where high levels of combustible gases are present, the ventilator is configured to direct the gases to a combustor. A gas detection sensor is included in the enclosure to monitor the interior of the enclosure. A processor receives data from the sensor and controls the removal of the combustible gases. The apparatus can further include a separator for separating the water from the hydrogen-rich reformate and directing the water into the collection vessel. The apparatus can include a separator for receiving and separating product water from a fuel cell exhaust stream and directing the product water to the collection vessel. In addition, collection vessel is connected to the outlet of a process water tank for receiving process water from the tank. Methods for manufacturing an apparatus for separating water from a reformate stream for safe disposal and methods for separating water from a reformate stream for safe disposal are disclosed.

Claims

1. A method for separating water from a reformate stream for safe disposal, the method comprising the steps of:

operating a fuel processor within a gas impermeable enclosure to produce a hydrogen-rich reformate comprising water and at least one combustible gas component;

separating the water from the hydrogen-rich reformate and directing the water to an open collection vessel within the enclosure; and

evaporating an entrained combustible gas component from the water to the interior of the enclosure.

2. The method of claim 1, further comprising the step of directing the water out of the collection vessel to a drain.

3. The method of claim 1, further comprising the step of detecting the presence of a combustible gas component within the interior of the enclosure.

4. The method of claim 3, further comprising the step of generating a signal when a combustible gas component is detected.

5. The method of claim 1, further comprising the step of evacuating a combustible gas component from the interior of the enclosure.

6. The method of claim 5, further comprising the step of combusting the evacuated combustible gas component.

7. The method of claim 1, further comprising the step of combusting the water-depleted hydrogen-rich reformate.

8. The method of claim 1, further comprising the steps of receiving a fuel cell exhaust mixture comprising an exhaust gas and product water, separating the product water from the exhaust gas and directing the product water to the open collection vessel.

9. The method of claim 8, further comprising the step of combusting the separated exhaust gas.

10. The method of claim 1, further comprising the step of withdrawing process water from a process water tank and directing the withdrawn process water to the open collection vessel.

11. A method for manufacturing an apparatus for separating water from a reformate stream for safe disposal, the method comprising the steps of:

enclosing a fuel processor in a gas impermeable enclosure, the fuel processor to produce a hydrogen-rich reformate comprising water and at least one combustible gas component

providing a separator for separating the water from the hydrogen-rich reformate; and

providing an open collection vessel within the enclosure for receiving separated water from the separator.

12. The method of claim 11, further comprising the step of providing a gas detection sensor in the enclosure for detecting the presence of a combustible gas component within the interior of the enclosure.

13. The method of claim 11, further comprising the step of providing a connection to a fuel cell for receiving fuel cell exhaust.

14. The method of claim 11, further comprising the step of providing the collection vessel with a drain connection.