Auxiliary reactor for a hydrocarbon reforming system

• US 6,986,797 B1
• Filed: 05/02/2000
• Issued: 01/17/2006
• Est. Priority Date: 05/03/1999
• Status: Expired due to Term

• Current Assignee: Hydrogen Fueling Corp.
• Original Assignee: Nuvera Fuel Cells, Inc. (Nacco Industries Incorporated)
• Inventors: Clawson, Lawrence G., Davis, Robert, Mitchell, William L., Dorson, Matthew H., Bentley, Jeffrey M., Nowicki, Brian J., Rumsey, Jennifer W.
• Primary Examiner(s): Ridley, Basia
• Application Number:
  US09/565,288
• Time in Patent Office: 2,086 Days
• Field of Search: 48/61, 48/2.R, 48/75, 48/63, 48/64, 48/89, 481/02.R, 481/05, 481/07, 481/02.A, 48/94, 482/14.A, 481/279, 481/28, 481/987, 482/11, 481/19, 481/981, 481/20, 481/983, 48/95, 482/14.R, 482/12, 482/13, 482/15, 122/4.D, 431/7, 431/173, 422187-198, 422200-204, 422/211, 422/222, 422/234, 422/235
• US Class Current: 48/102.00A
• CPC Class Codes: B01J 19/0013 Controlling the temperature of the process
• CPC Class Codes: B01J 2219/00006 Large-scale industrial plants
• CPC Class Codes: B01J 2219/00157 by means of a burner
• CPC Class Codes: B01J 2219/00159 controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
• CPC Class Codes: C01B 2203/0244 the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• CPC Class Codes: C01B 2203/0288 containing two CO-shift steps
• CPC Class Codes: C01B 2203/044 Selective oxidation of carbon monoxide
• CPC Class Codes: C01B 2203/047 the impurity being carbon monoxide
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/0822 the fuel containing hydrogen
• CPC Class Codes: C01B 2203/0827 at least part of the fuel being a recycle stream
• CPC Class Codes: C01B 2203/0844 the non-combustive exothermic reaction being another reforming reaction as defined in groups C01B2203/02 - C01B2203/0294
• CPC Class Codes: C01B 2203/142 At least two reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C01B 2203/146 At least two purification steps in series
• CPC Class Codes: C01B 2203/82 Several process steps of C01B2203/02 - C01B2203/08 integrated into a single apparatus
• CPC Class Codes: C01B 3/48 followed by reaction of water vapour with carbon monoxide
• CPC Class Codes: Y02P 20/10 Process efficiency

Abstract

An auxiliary reactor for use with a reformer reactor having at least one reaction zone, and including a burner for burning fuel and creating a heated auxiliary reactor gas stream, and heat exchanger for transferring heat from auxiliary reactor gas stream and heat transfer medium, preferably two-phase water, to reformer reaction zone. Auxiliary reactor may include first cylindrical wall defining a chamber for burning fuel and creating a heated auxiliary reactor gas stream, the chamber having an inlet end, an outlet end, a second cylindrical wall surrounding first wall and a second annular chamber there between. The reactor being configured so heated auxiliary reactor gas flows out the outlet end and into and through second annular chamber and conduit which is disposed in second annular chamber, the conduit adapted to carry heat transfer medium and being connectable to reformer reaction zone for additional heat exchange.

Claims

1. An auxiliary reactor for use in conjunction with a reformer reactor for converting hydrocarbons to hydrogen gas, the reformer reactor having at least a first reaction zone within, the auxiliary reactor comprising:

a first burner for burning a first fuel and creating a heated auxiliary reactor gas stream;

a first heat exchanger for transferring heat from at least the auxiliary reactor gas stream to a heat transfer medium, wherein the heat transfer medium is transferred from the auxiliary reactor to the first reaction zone for additional heat exchange with said first reaction zone without itself being a reactant of hydrocarbon combustion.

2. The auxiliary reactor of claim 1 further comprising a second burner, the second burner also providing heated auxiliary reactor gas which is in heat transfer with the heat transfer medium.

3. The auxiliary reactor of claim 2 wherein the first burner is a flame-type, gas-phase burner and the second burner is a catalytic burner, and wherein the auxiliary reactor is configured such that the first fuel is flowed first to the first burner to form a heated gas stream and the heated gas stream is then directed to the second burner.

4. The auxiliary reactor of claim 3 further comprising an inlet for connecting to a fuel cell for receiving gases exhausted from the fuel cell, the inlet is configured to deliver fuel cell exhaust gases into the auxiliary reactor gas stream to upstream of the catalytic burner to be catalytically burned.

5. The auxiliary reactor of claim 4 further comprising a second heat exchanger for exchanging heat from the auxiliary reactor gas stream to a secondary fuel to be fed to the reformer for reforming.

6. The auxiliary reactor of claim 5 wherein the second heat exchanger includes a catalyst through which the secondary fuel flows for removing sulfur from the secondary fuel before it is fed to the reformer.

7. The auxiliary reactor of claim 6 wherein the at least first reaction zone includes a catalyst for performing a water-gas shift reaction.

8. The auxiliary reactor of claim 7 wherein the catalyst performs a water-gas shift reaction in the temperature range of from about 300°

F. to about 600°

F.

9. The auxiliary reactor of claim 6 wherein the catalyst through which the secondary fuel flows for removing sulfur, contains zinc.

10. The auxiliary reactor of claim 2 further comprising a second heat exchanger for exchanging heat from the auxiliary reactor gas stream to a secondary fuel to be fed to the reformer for reforming.

11. The auxiliary reactor of claim 10 wherein the second heat exchanger includes a catalyst through which the secondary fuel flows for removing sulfur from the secondary fuel before it is fed to the reformer.

12. The auxiliary reactor of claim 11 wherein the at least first reaction zone includes a catalyst for performing a water-gas shift reaction.

13. The auxiliary reactor of claim 12 wherein the catalyst performs a water-gas shift reaction in the temperature range of from about 300°

F. to about 600°

F.

14. The auxiliary reactor of claim 11 wherein the catalyst through which the secondary fuel flows for removing sulfur, contains zinc.

15. The auxiliary reactor of claim 10 further comprising an inlet for connecting to a fuel cell for receiving gases exhausted from the fuel cell, the inlet being configured to deliver fuel cell exhaust gases into the auxiliary reactor gas stream upstream of the second burner to be burned.

16. The auxiliary reactor of claim 15 wherein the at least first reaction zone includes a catalyst for performing a water-gas shift reaction.

17. The auxiliary reactor of claim 16 wherein the catalyst performs a water-gas shift reaction in the temperature range of from about 300°

F. to about 600°

F.

18. The auxiliary reactor of claim 10 wherein the second heat exchanger includes a catalyst through which the secondary fuel flows for removing sulfur from the secondary fuel before it is fed to the reformer.

19. The auxiliary reactor of claim 10 wherein the at least first reaction zone includes a catalyst for performing a water-gas shift reaction.

20. The auxiliary reactor of claim 19 wherein the catalyst performs a water-gas shift reaction in the temperature range of from about 300°

F. to about 600°

F.

21. The auxiliary reactor of claim 2 further comprising an inlet for connecting to a fuel cell for receiving gases exhausted from the fuel cell, the inlet is configured to deliver fuel cell exhaust gases into the auxiliary reactor gas stream upstream of the second burner to be burned.

22. The auxiliary reactor of claim 1 further comprising a second heat exchanger for exchanging heat from the auxiliary reactor gas stream to a secondary fuel to be fed to the reformer for reforming.

23. The auxiliary reactor of claim 22 wherein the second heat exchanger includes a catalyst through which the secondary fuel flows for removing sulfur from the secondary fuel before it is fed to the reformer.

24. The auxiliary reactor of claim 23 wherein the catalyst through which the secondary fuel flows for removing sulfur, contains zinc.

25. The auxiliary reactor of claim 22 wherein the at least first reaction zone includes a catalyst for performing a water-gas shift reaction.

26. The auxiliary reactor of claim 25 wherein the catalyst performs a water-gas shift reaction in the temperature range of from about 300°

F. to about 600°

F.

27. The auxiliary reactor of claim 1 further comprising an inlet for connecting to a fuel cell for receiving gases exhausted from the fuel cell.

28. The auxiliary reactor of claim 27 wherein the inlet is configured to deliver fuel cell exhaust gases into the auxiliary reactor gas stream upstream of the second burner to be burned.

29. The auxiliary reactor of claim 1 including a third heat exchanger for exchanging heat from the auxiliary reactor gas stream to a stream of oxygen-containing gas, which gas is supplied to the first burner.

30. The auxiliary reactor of claim 1 wherein the at least first reaction zone includes a catalyst for performing a water-gas shift reaction.

31. The auxiliary reactor of claim 30 wherein the catalyst performs a water-gas shift reaction in the temperature range of from about 300°

F. to about 600°

F.