Plate type reformer assembly

• US 5,180,561 A
• Filed: 11/26/1990
• Issued: 01/19/1993
• Est. Priority Date: 11/27/1989
• Status: Expired due to Term

• Current Assignee: Ishikawajima-Harima Heavy Industries Company Limited
• Original Assignee: Ishikawajima-Harima Heavy Industries Company Limited
• Inventors: Morishima, Satoshi, Chidiiwa, Sakae
• Primary Examiner(s): Warden, Robert J.
• Assistant Examiner(s): Thornton, Krisanne M.
• Application Number:
  US07/617,996
• Time in Patent Office: 785 Days
• Field of Search: 422/188, 422/191, 422/202, 422/204, 48/127.9, 48/198.7, 48/94, 429/17, 429/19
• US Class Current: 422/643
• CPC Class Codes: B01J 19/249 Plate-type reactors
• CPC Class Codes: B01J 2219/2453 Plates arranged in parallel
• CPC Class Codes: B01J 2219/2458 Flat plates, i.e. plates which are not corrugated or otherwise structured, e.g. plates with cylindrical shape
• CPC Class Codes: B01J 2219/247 Feeding means for the reactants
• CPC Class Codes: B01J 2219/2471 Feeding means for the catalyst
• CPC Class Codes: B01J 2219/2481 Catalysts in granular from between plates
• CPC Class Codes: B01J 2219/2493 Means for assembling plates together, e.g. sealing means, screws, bolts
• CPC Class Codes: B01J 2219/2496 Means for assembling modules together, e.g. casings, holders, fluidic connectors
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/1011 Packed bed of catalytic structures, e.g. particles, packing elements
• CPC Class Codes: C01B 2203/1058 Nickel catalysts
• CPC Class Codes: C01B 2203/1241 Natural gas or methane
• CPC Class Codes: C01B 3/38 using catalysts
• CPC Class Codes: H01M 8/0625 in a modular combined reactor/fuel cell structure
• 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: Y02E 60/50 Fuel cells

Abstract

A reformer assembly includes fuel introduction plates, combustion chamber plates and reforming chamber plates. The fuel introduction plate includes a first plate member and a first masking frame on the periphery of the first plate member. The combustion chamber plate includes a second plate member and a second masking frame on the periphery of the second plate member, and combustion catalyst is placed in the combustion chamber plate. The reforming chamber plate includes a third plate member and a third masking frame on the periphery of the third plate member, and reforming catalyst is placed in the reforming chamber plate. The first masking frame has a fuel feeding port. The second plate member has a number of dispersion holes and the second masking frame has air feeding and exhaust gas discharging ports. The third masking frame has raw material gas feeding and reformed gas discharging ports. These plates are stacked to define a multi-layer unit. The peripheries of the adjacent stacked plates are welded to each other. Manifolds for the aligned gas feeding and discharging ports are mounted on lateral faces of the unit. Sealing is unnecessary between the plates due to the welding. In addition, the feeding and discharging of the various gases become easy since the manifolds are mounted on the multi-layer unit.

Claims

1. A reformer assembly, comprising:

a multi-layer unit including fuel introduction plates, combustion chamber plates, reforming chamber plates and a separation plate,

each fuel introduction plate having a first plate member and a first masking frame, the first masking frame being integrally mounted on the periphery of the first plate member, a fuel feeding port being formed in the first masking frame, a pair of first partition members being provided on the fuel introduction plate, each partition member having a crenellated structure, a fuel introduction room being defined between the pair of first partition members, a first entrance room and a first exit room being defined outside the first partition members respectively, the fuel feeding port being open to the first entrance room,

each combustion chamber plate having a second plate member and a second masking frame, the second masking frame being integrally mounted on the periphery of the second plate member, and an air feeding port, an exhaust gas discharging port and a combustion catalyst insertion opening being respectively formed in the second masking frame, a pair of second partition members being provided on the combustion chamber plate, each second partition member having a crenellated structure, a combustion chamber being formed between the second pair of partition members, a second entrance room and a second exit room being defined outside the second pair of partition members respectively, the second plate member having a plurality of dispersion openings between the pair of second partition members, the air feeding port being open to the second entrance room, the exhaust gas discharging port being open to the second exit room, the combustion catalyst insertion opening being open to the combustion chamber, the combustion catalyst insertion opening being aligned with one of the second partition members such that a combustion catalyst moves to the combustion catalyst insertion opening along the one of the second partition members when the combustion catalyst is withdrawn out of the combustion chamber through the combustion catalyst insertion opening,

each reforming chamber plate having a third plate member and a third masking frame, the third masking frame being integrally mounted on the periphery of the third plate member, and a raw material gas feeding port, a reformed gas discharging port and a reforming catalyst insertion opening being respectively formed in the third masking frame, a third pair of partition members being provided on the reforming chamber plate, each third partition member having a crenellated structure, a reforming chamber being defined between the pair of third partition members, a third entrance room and a third exit room being defined outside the pair of third partition members respectively, the raw material gas feeding port being open to the third entrance room, the reformed gas discharging port being open to the third exit room, the reforming catalyst insertion opening being open to the reforming chamber, the reforming catalyst insertion opening being aligned with one of the third partition members such that a reforming catalyst moves to the reforming catalyst insertion opening along the one of the third partition members when the reforming catalyst is withdrawn out of the reforming chamber through the reforming catalyst insertion opening, the fuel introduction plates, the combustion chamber plates and the reforming chamber plates being stacked in turn to define multiple layers, a top one of said layers being referred to as an uppermost layer, the multi-layer unit having a lateral face, with the feeding ports, discharging ports, combustion catalyst insertion openings and reforming catalyst insertion openings being respectively aligned in a direction in which the plates are stacked, the separation plate being provided on the reforming chamber plate of the uppermost layer of the unit, the fuel introduction plate, the combustion chamber plate, the reforming chamber plate and the separation plate being connected to each other at the peripheries thereof;

manifolds attached to the lateral face of the multi-layer unit to cover the feeding and discharging ports;

a combustion catalyst layer being defined by a combustion catalyst in each combustion chamber plate;

a reforming catalyst layer being defined by a reforming catalyst in each reforming chamber plate;

first sealing means for opening and closing the combustion catalyst insertion openings; and

second sealing means for opening and closing the reforming catalyst insertion openings.

2. The assembly of claim 1, wherein the fuel introduction plates, combustion chamber plates, reforming chamber plates, and separation plate each have a plurality of spacer members on the corresponding plate member thereof, the plurality of spacer members having the same height as the corresponding masking frame.

3. The assembly of claim 2, wherein the plurality of dispersion openings of the combustion chamber plate are formed in the second plate member between the pair of second partition members.

4. The assembly of claim 3, wherein the plurality of dispersion openings are not formed in a predetermined area near the pair of second partition members on the second exit room side.

5. The assembly of claim 1, wherein the combustion catalyst of the combustion catalyst layer is shaped like spheres.

6. The assembly of claim 5, wherein the reforming catalyst of the reforming catalyst layer is shaped like spheres.

7. The assembly of claim 1, wherein the multi-layer unit is formed in a manner such that the entrance rooms and the exit rooms of the fuel introduction plates, the combustion chamber plates and the reforming chamber plates are respectively aligned in a direction in which the fuel introduction plates, the combustion chamber plates and the reforming chamber plates are stacked.

8. The assembly of claim 7, wherein the multi-layer unit has four lateral faces, arranged in two pairs of faces facing each other, and the air feeding port and the combustion catalyst insertion opening of the combustion chamber plate are formed in a lateral face facing an opposite face in which the raw material gas feeding port and the reforming catalyst insertion opening of the reforming chamber plate are formed.

9. The assembly of claim 8, wherein the manifolds include a connecting cylinder welded on the lateral face of the multi-layer unit which covers the feeding and discharging ports and a flange connected to the connecting cylinder.

10. The assembly of claim 9, wherein the sealing means includes a plate having a slit-like opening corresponding to the catalyst insertion openings and welded on the lateral face of the multi-layer unit and a sealing plate mounted on the plate by means of screws.

11. The assembly of claim 8, wherein the manifolds include a raw material gas feeding manifold and a air feeding manifold which respectively have a configuration to cover the feeding ports and the catalyst insertion openings, and the catalyst insertion openings are provided with sealing means to seal the catalyst insertion openings.

12. The assembly of claim 8, wherein the fuel introduction plates, combustion chamber plates, reforming chamber plates, and separation plate are welded by welding of the periphery of the adjacent plates.

13. The assembly of claim 1, wherein a first pair of upper and lower supporting plates are mounted on the top and the bottom of the multi-layer unit, and a second pair of upper and lower plates are mounted on the first pair of upper and lower supporting plates.

14. A reformer assembly, comprising:

a multi-layer unit including fuel introduction plates, combustion chamber plates, reforming chamber plates and a separation plate,

each fuel introduction plate having a first plate member and a first masking frame, the first masking frame being integrally mounted on the periphery of the first plate member and a fuel feeding port being formed in the first masking frame,

each combustion chamber plate having a second plate member and a second masking frame, the second masking frame being integrally mounted on the periphery of the second plate member, a plurality of dispersion holes being formed in the second plate member, and an air feeding port and an exhaust gas discharging port being respectively formed in the second masking frame,

each reforming chamber plate having a third plate member and a third masking frame, the third masking frame being integrally mounted on the periphery of the third plate member, and a raw material gas feeding port and a reformed gas discharging port being respectively formed in the third masking frame, the third masking frame containing a reforming catalyst

the fuel introduction plates, the combustion chamber plates and the reforming chamber plates being stacked in turn to define multiple layers, a top one of said layers being referred to as an uppermost layer, the multi-layer unit having a direction in which the plates are stocked and a lateral face, with the feeding ports and discharging ports, being aligned respectively in the direction in which the plates are stacked, the separation plate being provided on the reforming chamber plate of the uppermost layer of the multi-layer unit, the fuel introduction plate, the combustion chamber plate, the reforming chamber plate and the separation plate being welded to each other at the peripheries thereof;

manifolds welded on the lateral face of the multi-layer unit to cover the feeding and discharging ports; and

means for insertion and removal of catalyst into and from at least one of the combustion chamber plates or the reforming chamber plates without disassembly of the multi-layer unit.

15. The assembly of claim 14, wherein the fuel introduction plates, combustion chamber plates, reforming chamber plates, and separation plate each have a pair of crenellated partition members on the corresponding plate member thereof to define a fuel introduction chamber, a combustion chamber or a reforming chamber between the partition members and to define an entrance room and an exit room outside the partition member, the partition member defining the entrance room being called entrance room side partition member and the partition member defining the exit room being called exit room side partition member.

16. The assembly of claim 15, wherein the partition member has a crenellated portion to allow gases to pass through the partition member via the crenellated portion.

17. The assembly of claim 16, wherein the fuel introduction plates, combustion chamber plates, reforming chamber plates, and separation plate each have a plurality of spacer members on the corresponding plate member thereof, the plurality of spacer members having the same height as the corresponding masking frame.

18. The assembly of claim 17, wherein the plurality of dispersion holes of the combustion chamber plate are formed in the second plate member between the partition members.

19. The assembly of claim 18, wherein the plurality of dispersion holes are not formed in a predetermined area near the partition member on the exit room side.

20. The assembly of claim 14, wherein the combustion chamber contains a combustion catalyst shaped like spheres.

21. The assembly of claim 15, wherein a combustion catalyst insertion and removal opening is formed aligned with one of the partition members of the combustion chamber plate on the entrance room side and the air feeding port is formed next to the combustion catalyst insertion and removal opening over the one partition member.

22. The assembly of claim 21, wherein a reforming catalyst insertion and removal opening is formed aligned with one of the partition members of the reforming chamber plate on the entrance room side and the raw material gas feeding port is formed next to the reforming catalyst insertion and removal opening over the one partition member.

23. The assembly of claim 22, wherein the multi-layer unit is formed in a manner such that the entrance rooms and the exit rooms of the fuel introduction plates, the combustion chamber plates and the reforming chamber plates are respectively aligned in a direction in which the fuel introduction plates, the combustion chamber plates and the reforming chamber plates are stacked.

24. The assembly of claim 23, wherein the multi-layer unit has four lateral faces, arranged in two pairs of faces facing each other, and the air feeding port and the combustion catalyst insertion and removal opening of the combustion chamber plate are formed in a lateral face facing an opposite face in which the raw material gas feeding port and the reforming catalyst insertion and removal opening of the reforming chamber plate are formed.

25. The assembly of claim 24, wherein each manifold includes a connecting cylinder welded on the lateral face of the multi-layer unit which covers the feeding and discharging ports and a flange connected to the connecting cylinder.

26. The assembly of claim 25, wherein the sealing means includes a plate having a slit-like opening corresponding to the catalyst insertion and removal opening and welded on the lateral face of the multi-layer unit and a sealing plate mounted on the plate by means of screws.

27. The assembly of claim 14, wherein the reforming catalyst contained within the third masking frame of the reforming chamber plate is shaped like spheres.

28. The assembly of claim 14, wherein the manifolds include a raw material gas feeding manifold and an air feeding manifold which respectively have a configuration to cover the feeding ports and the catalyst insertion and removal openings, and the catalyst insertion and removal openings are provided with sealing means to seal the catalyst insertion and removal openings.

29. The assembly of claim 14, wherein a first pair of upper and lower supporting plates are mounted on the top and the bottom of the multi-layer unit, and a second pair of upper and lower plates are mounted on the first pair of upper and lower supporting plates.