Pre-reformer for selective reformation of higher hydrocarbons

• US 9,287,572 B2
• Filed: 10/21/2014
• Issued: 03/15/2016
• Est. Priority Date: 10/23/2013
• Status: Active Grant

• Current Assignee: Bloom Energy Corporation
• Original Assignee: Bloom Energy Corporation
• Inventors: Weingaertner, David, Kalika, Vlad, Perry, Martin
• Primary Examiner(s): DOVE, TRACY MAE
• Application Number:
  US14/519,560
• Publication Number:
  US 20150111121A1
• Time in Patent Office: 511 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: C01B 2203/066 with fuel cells
• CPC Class Codes: C01B 2203/1058 Nickel catalysts
• CPC Class Codes: C01B 2203/1064 Platinum group metal catalysts
• CPC Class Codes: C01B 3/38 using catalysts
• CPC Class Codes: H01M 2008/1293 Fuel cells with solid oxide electrolytes
• CPC Class Codes: H01M 8/004 Cylindrical, tubular or wound
• CPC Class Codes: H01M 8/0618 Reforming processes, e.g. autothermal, partial oxidation or steam reforming
• 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 8/0637 Direct internal reforming at the anode of the fuel cell
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

Systems and methods are provided integrating an annular pre-reformer as part of an anode recuperator of a fuel cell system.

Claims

1. An anode recuperator for a fuel cell system, comprising:

a first annular fuel passage, wherein an inner wall of the first annular fuel passage is configured to form an upper plenum surrounded by the first annular fuel passage;

an annular pre-reformer coupled to the first annular fuel passage and configured to receive an unreformed fuel stream from the first annular fuel passage and at least partially reform the unreformed fuel stream to generate a reformed fuel stream, the annular pre-reformer located axially inward of the first annular fuel passage; and

an annular anode exhaust passage surrounding at least a portion of the first annular fuel passage and the annular pre-reformer, the annular anode exhaust passage thermally coupled to the first annular fuel passage such that an anode exhaust stream in the annular anode exhaust passage provides heat to the unreformed fuel stream in the first annular fuel passage, wherein the annular pre-reformer is separated from the annular anode exhaust passage;

further comprising a second annular fuel passage coupled to the annular pre-reformer and configured to receive the reformed fuel stream from the annular pre-reformer;

wherein;

an inner wall of the second annular fuel passage is configured to form a lower plenum surrounded by the second annular fuel passage;

the annular anode exhaust passage surrounds at least a portion of the second annular fuel passage and the annular anode exhaust passage is thermally coupled to the second annular fuel passage such that the anode exhaust stream in the annular anode exhaust passage provides heat to the reformed fuel stream in the second annular fuel passage; and

the annular pre-reformer is separated from the annular anode exhaust passage by the first annular fuel passage or the second annular fuel passage; and

wherein;

the annular pre-reformer includes a first annular pre-reforming passage and a second annular pre-reforming passage, the first annular pre-reforming passage encircling the second annular pre-reforming passage; and

the first annular pre-reforming passage is configured to receive the unreformed fuel stream from the first annular fuel passage and the second annular pre-reforming passage is configured to provide the reformed fuel stream to the second annular fuel passage.

2. The anode recuperator of claim 1, wherein a pre-reformer catalyst is located in both the first annular pre-reforming passage and the second annular pre-reforming passage.

3. The anode recuperator of claim 2, wherein:

an inner wall of the second annular pre-reformer passage is configured to form a hollow plenum surrounded by the second annular pre-reformer passage; and

the pre-reformer catalyst is not located in the hollow plenum.

4. The anode recuperator of claim 1, wherein a pre-reformer catalyst is located only in the second annular pre-reformer passage and is not located in the first annular pre-reforming passage.

5. An anode recuperator for a fuel cell system, comprising:

a first annular fuel passage, wherein an inner wall of the first annular fuel passage is configured to form an upper plenum surrounded by the first annular fuel passage;

an annular pre-reformer coupled to the first annular fuel passage and configured to receive an unreformed fuel stream from the first annular fuel passage and at least partially reform the unreformed fuel stream to generate a reformed fuel stream, the annular pre-reformer located axially inward of the first annular fuel passage; and

an annular anode exhaust passage surrounding at least a portion of the first annular fuel passage and the annular pre-reformer, the annular anode exhaust passage thermally coupled to the first annular fuel passage such that an anode exhaust stream in the annular anode exhaust passage provides heat to the unreformed fuel stream in the first annular fuel passage,

wherein the annular pre-reformer is separated from the annular anode exhaust passage;

further comprising a second annular fuel passage coupled to the annular pre-reformer and configured to receive the reformed fuel stream from the annular pre-reformer;

wherein;

an inner wall of the second annular fuel passage is configured to form a lower plenum surrounded by the second annular fuel passage;

the annular anode exhaust passage surrounds at least a portion of the second annular fuel passage and the annular anode exhaust passage is thermally coupled to the second annular fuel passage such that the anode exhaust stream in the annular anode exhaust passage provides heat to the reformed fuel stream in the second annular fuel passage; and

the annular pre-reformer is separated from the annular anode exhaust passage by the first annular fuel passage or the second annular fuel passage; and

wherein;

the annular pre-reformer includes a first annular pre-reforming passage and a second annular pre-reforming passage, the first annular pre-reforming passage encircling the second annular pre-reforming passage; and

the second annular pre-reforming passage is configured to receive the unreformed fuel stream from the first annular fuel passage and the first annular pre-reforming passage is configured to provide the reformed fuel stream to the second annular fuel passage.

6. The anode recuperator of claim 5, wherein a pre-reformer catalyst is located in both the first annular pre-reforming passage and the second annular pre-reforming passage.

7. The anode recuperator of claim 6, wherein:

an inner wall of the second annular pre-reformer passage is configured to form a hollow plenum surrounded by the second annular pre-reformer passage; and

the pre-reformer catalyst is not located in the hollow plenum.

8. The anode recuperator of claim 5, wherein a pre-reformer catalyst is located only in the second annular pre-reformer passage and is not located in the first annular pre-reforming passage.

9. An anode recuperator for a fuel cell system, comprising:

a first annular fuel passage, wherein an inner wall of the first annular fuel passage is configured to form an upper plenum surrounded by the first annular fuel passage;

an annular pre-reformer coupled to the first annular fuel passage and configured to receive an unreformed fuel stream from the first annular fuel passage and at least partially reform the unreformed fuel stream to generate a reformed fuel stream, the annular pre-reformer located axially inward of the first annular fuel passage; and

an annular anode exhaust passage surrounding at least a portion of the first annular fuel passage and the annular pre-reformer, the annular anode exhaust passage thermally coupled to the first annular fuel passage such that an anode exhaust stream in the annular anode exhaust passage provides heat to the unreformed fuel stream in the first annular fuel passage,

wherein the annular pre-reformer is separated from the annular anode exhaust passage; and

wherein;

the annular pre-reformer includes a first annular pre-reforming passage and a second annular pre-reforming passage, the first annular pre-reforming passage encircling the second annular pre-reforming passage;

the first annular pre-reforming passage is configured to receive the unreformed fuel stream from the first annular fuel passage and the second annular pre-reforming passage is configured to provide the reformed fuel stream to an anode feed manifold; and

a pre-reformer catalyst is located only in the second annular pre-reformer passage and is not located in the first annular pre-reforming passage.

10. The anode recuperator of claim 9, wherein the anode feed manifold includes an inner cylindrical space and an outer ring concentrically aligned in a same plane, the inner cylindrical space configured to receive the reformed fuel stream from the second annular pre-reforming passage and the outer ring configured to provide the anode exhaust stream to the annular anode exhaust passage.

11. The anode recuperator of claim 10, wherein the annular anode exhaust passage is an annular corrugated finned wall.

12. A method of operating an anode recuperator of a fuel cell system, comprising:

pre-reforming an unreformed fuel stream at a temperature less than or equal to 750 degrees Celsius to selectively reform higher hydrocarbons in the unreformed fuel stream over methane in the unreformed fuel stream to generate a reformed fuel stream;

providing the unreformed fuel stream from a first annular fuel passage to an annular pre-reformer, wherein an inner wall of the first annular fuel passage is configured to form an upper plenum surrounded by the first annular fuel passage and the annular pre-reformer is coupled to the first annular fuel passage;

at least partially reforming the unreformed fuel stream in the annular pre-reformer to generate the reformed fuel stream;

providing an anode exhaust stream in an annular anode exhaust passage to provide heat to the unreformed fuel stream in the first annular fuel passage, the annular anode exhaust passage surrounding at least a portion of the first annular fuel passage and the annular pre-reformer;

providing the reformed fuel stream to a second annular fuel passage coupled to the annular pre-reformer, wherein an inner wall of the second annular fuel passage is configured to form a lower plenum surrounded by the second annular fuel passage; and

providing the anode exhaust stream in the annular anode exhaust passage to provide heat to the reformed fuel stream in the second annular fuel passage, the annular anode exhaust passage surrounding at least a portion of the second annular fuel passage;

wherein the annular pre-reformer is located axially inward of the first annular fuel passage and the annular pre-reformer is separated from the annular anode exhaust passage by the first annular fuel passage or the second annular fuel passage; and

wherein the annular pre-reformer includes a first annular pre-reforming passage and a second annular pre-reforming passage, the first annular pre-reforming passage encircling the second annular pre-reforming passage, the method further comprising;

receiving the unreformed fuel stream from the first annular fuel passage in the first annular pre-reforming passage; and

providing the reformed fuel stream to the second annular fuel passage from the second annular pre-reforming passage.

13. The method of claim 12, wherein pre-reformer catalyst is located in both the first annular pre-reforming passage and the second annular pre-reforming passage.

14. The method of claim 13, wherein:

an inner wall of the second annular pre-reformer passage forms a hollow plenum surrounded by the second annular pre-reformer passage; and

the pre-reformer catalyst is not located in the hollow plenum.

15. The method of claim 12, wherein pre-reformer catalyst is located in the second annular pre-reforming passage and is not located in the first annular pre-reforming passage.

16. A method of operating an anode recuperator of a fuel cell system, comprising:

pre-reforming an unreformed fuel stream at a temperature less than or equal to 750 degrees Celsius to selectively reform higher hydrocarbons in the unreformed fuel stream over methane in the unreformed fuel stream to generate a reformed fuel stream;

providing the unreformed fuel stream from a first annular fuel passage to an annular pre-reformer, wherein an inner wall of the first annular fuel passage is configured to form an upper plenum surrounded by the first annular fuel passage and the annular pre-reformer is coupled to the first annular fuel passage;

at least partially reforming the unreformed fuel stream in the annular pre-reformer to generate the reformed fuel stream;

providing an anode exhaust stream in an annular anode exhaust passage to provide heat to the unreformed fuel stream in the first annular fuel passage, the annular anode exhaust passage surrounding at least a portion of the first annular fuel passage and the annular pre-reformer;

providing the reformed fuel stream to a second annular fuel passage coupled to the annular pre-reformer, wherein an inner wall of the second annular fuel passage is configured to form a lower plenum surrounded by the second annular fuel passage; and

providing the anode exhaust stream in the annular anode exhaust passage to provide heat to the reformed fuel stream in the second annular fuel passage, the annular anode exhaust passage surrounding at least a portion of the second annular fuel passage;

wherein the annular pre-reformer is located axially inward of the first annular fuel passage and the annular pre-reformer is separated from the annular anode exhaust passage by the first annular fuel passage or the second annular fuel passage; and

wherein the annular pre-reformer includes a first annular pre-reforming passage and a second annular pre-reforming passage, the first annular pre-reforming passage encircling the second annular pre-reforming passage, the method further comprising;

receiving the unreformed fuel stream from the first annular fuel passage in the second annular pre-reforming passage; and

providing the reformed fuel stream to the second annular fuel passage from the first annular pre-reforming passage.

17. The method of claim 16, wherein pre-reformer catalyst is located in both the first annular pre-reforming passage and the second annular pre-reforming passage.

18. The method of claim 17, wherein:

an inner wall of the second annular pre-reformer passage forms a hollow plenum surrounded by the second annular pre-reformer passage; and

the pre-reformer catalyst is not located in the hollow plenum.

19. The method of claim 16, wherein pre-reformer catalyst is located in the second annular pre-reforming passage and is not located in the first annular pre-reforming passage.

20. A method of operating an anode recuperator of a fuel cell system, comprising:

pre-reforming an unreformed fuel stream at a temperature less than or equal to 750 degrees Celsius to selectively reform higher hydrocarbons in the unreformed fuel stream over methane in the unreformed fuel stream to generate a reformed fuel stream;

providing the unreformed fuel stream from a first annular fuel passage to an annular pre-reformer, wherein an inner wall of the first annular fuel passage is configured to form an upper plenum surrounded by the first annular fuel passage and the annular pre-reformer is coupled to the first annular fuel passage;

at least partially reforming the unreformed fuel stream in the annular pre-reformer to generate the reformed fuel stream; and

providing an anode exhaust stream in an annular anode exhaust passage to provide heat to the unreformed fuel stream in the first annular fuel passage, the annular anode exhaust passage surrounding at least a portion of the first annular fuel passage and the annular pre-reformer; and

wherein;

the annular pre-reformer is located axially inward of the first annular fuel passage;

the annular pre-reformer is separated from the annular anode exhaust passage; and

the annular pre-reformer includes a first annular pre-reforming passage and a second annular pre-reforming passage, the first annular pre-reforming passage encircling the second annular pre-reforming passage,

the method further comprising;

receiving the unreformed fuel stream from the first annular fuel passage in the first annular pre-reforming passage;

receiving the unreformed fuel stream in the second annular pre-reforming passage from the first annular pre-reforming passage;

at least partially reforming the unreformed fuel stream in the second annular pre-reforming passage to generate the reformed fuel stream; and

providing the reformed fuel stream to an anode feed manifold from the second annular pre-reforming passage,

wherein a pre-reformer catalyst is located only in the second annular pre-reformer passage and is not located in the first annular pre-reforming passage.

21. The method of claim 20, wherein the anode feed manifold includes an inner space and an outer ring concentrically aligned in a same plane, the method further comprising:

receiving the reformed fuel stream from the second annular pre-reforming passage in the inner space; and

providing the anode exhaust stream to the annular anode exhaust passage from the outer ring.