Catalytic hydrocarbon reformer with enhanced internal heat transfer mechanism

• US 5,484,577 A
• Filed: 05/27/1994
• Issued: 01/16/1996
• Est. Priority Date: 05/27/1994
• Status: Expired due to Term

• Current Assignee: Ballard Power Systems Corporation (Superior Plus Corporation)
• Original Assignee: Ballard Power Systems Corporation (Superior Plus Corporation)
• Inventors: Clausi, Joseph V., Leavitt, Stanley L., Cohen, Ronald, Watkins, David S., Buswell, Richard F.
• Primary Examiner(s): McMahon, Timothy M.
• Application Number:
  US08/250,371
• Time in Patent Office: 599 Days
• Field of Search: 422/148, 422/211, 422/213, 422/220, 422/221, 422/197, 422/190, 422/193, 422/196, 208/134
• US Class Current: 422/211
• CPC Class Codes: B01J 8/062 being installed in a furnace
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/04 containing a purification step for the hydrogen or the synthesis gas
• CPC Class Codes: C01B 2203/066 with fuel cells
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/0816 Heating by flames
• CPC Class Codes: C01B 2203/0827 at least part of the fuel being a recycle stream
• CPC Class Codes: C01B 2203/0866 by combination of different heating methods
• CPC Class Codes: C01B 2203/1011 Packed bed of catalytic structures, e.g. particles, packing elements
• CPC Class Codes: C01B 2203/1235 Hydrocarbons
• CPC Class Codes: C01B 2203/1241 Natural gas or methane
• CPC Class Codes: C01B 2203/148 involving a recycle stream to the feed of the process for making hydrogen or synthesis gas
• CPC Class Codes: C01B 3/384 the catalyst being continuously externally heated
• 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 catalytic hydrocarbon reformer operates at lower temperature and pressure relative to conventional reformers. Convective heat transfer between the hot combustion gas stream and the reactor tube is enhanced through use of a narrow gap heat transfer area, which induces turbulent flow of the combustion gas stream across the reactor tube. The reactor tube includes a catalyst fines collection tube to accumulate and retain catalyst particles or fines entrained in the reformate gas stream.

Claims

1. A catalytic hydrocarbon reformer for converting raw hydrocarbon fuel into a reformate gas stream comprising hydrogen, said reformer comprising:

(a) a substantially cylindrical closed vessel, said vessel having a top end and a bottom end, said vessel comprising at least one insulation layer adjacent the interior surface of its side wall;

(b) at least one substantially cylindrical reactor tube disposed within said reformer vessel, said reactor tube comprising an outer annular catalyst chamber defined by the volume between said exterior surface and a concentric inner gas return tube;

(c) a burner disposed within said reformer vessel, said burner capable of generating and directing a combustion gas stream toward the bottom of said reactor vessel and toward said reactor tube assembly;

(d) an exhaust guide sleeve disposed between said reactor tube and said at least one insulation layer, said exhaust guide sleeve being concentric with said reactor tube; and

(e) a catalyst fines collection tube having a separator affixed at or near the top thereof, said collection tube concentrically disposed within said gas return tube such that a gas return annulus is formed between said annular catalyst chamber and said collection tube;

wherein the radial distance between said reactor tube and said exhaust guide sleeve is sufficiently small to cause flow of said combustion gas stream along the exterior surface of the reactor tube assembly to be turbulent.

2. The catalytic hydrocarbon reformer of claim 1 wherein said at least one insulation layer comprises a plurality of insulation layers, each of said insulation layers having a different heat transfer coefficient.

3. The catalytic hydrocarbon reformer of claim 1 wherein said at least one reactor tube comprises a plurality of reactor tubes.

4. A catalytic hydrocarbon reformer for converting raw hydrocarbon fuel into a reformat gas stream comprising hydrogen, said reformer comprising:

(a) a substantially cylindrical closed vessel, said vessel having a top end and a bottom end, said vessel optimizing at least one insulation layer adjacent the interior surface of its side wall;

(b) at least one substantially cylindrical reactor tube disposed within said reformer vessel, said reactor tube comprising an outer annular catalyst chamber defined by the volume between said exterior surface and a concentric inner gas return tube;

(c) a burner disposed within said reformer vessel, said burner capable of generating and directing a combustion gas stream toward the bottom of said reactor vessel and toward said reactor tube assembly;

(d) an exhaust guide sleeve disposed between said reactor tube and said at least one insulation layer, said exhaust guide sleeve being concentric with said reactor tube; and

(e) a catalyst fines collection tube having a separator affixed at or near the top thereof, said collection tube concentrically disposed within said gas return tube such that a gas return annulus is formed between said annular catalyst chamber and said collection tube.