Fuel processing device

• US 7,988,925 B2
• Filed: 01/03/2008
• Issued: 08/02/2011
• Est. Priority Date: 02/14/2003
• Status: Expired due to Fees

• Current Assignee: UChicago Argonne LLC
• Original Assignee: UChicago Argonne LLC
• Inventors: Ahluwalia, Rajesh K., Lee, Sheldon H. D., Ahmed, Shabbir
• Primary Examiner(s): Caldarola; Glenn
• Assistant Examiner(s): Boyer; Randy
• Application Number:
  US12/006,468
• Publication Number:
  US 20090087358A1
• Time in Patent Office: 1,307 Days
• Field of Search: 48/62.R, 422/198
• US Class Current: 422/198
• CPC Class Codes: B01J 2208/00061 of the reactants
• CPC Class Codes: B01J 2208/00141 Coils
• CPC Class Codes: B01J 2208/00398 inside the reactor bed
• CPC Class Codes: B01J 2208/00415 electric resistance heaters
• CPC Class Codes: B01J 2208/00495 using insulating materials or refractories
• CPC Class Codes: B01J 2208/00628 Controlling the composition of the reactive mixture
• CPC Class Codes: B01J 2208/00716 Means for reactor start-up
• CPC Class Codes: B01J 2219/002 inside the reactor
• CPC Class Codes: B01J 2219/00213 Fixed parameter value
• CPC Class Codes: B01J 2219/00231 at the reactor inlet
• CPC Class Codes: B01J 8/025 in a cylindrical shaped bed
• CPC Class Codes: B01J 8/0278 Feeding reactive fluids for solid material B01J8/0015
• CPC Class Codes: B01J 8/0285 Heating or cooling the reactor for tubular reactors in furnaces B01J8/062
• CPC Class Codes: C01B 2203/0244 the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• CPC Class Codes: C01B 2203/0261 containing a catalytic partial oxidation step [CPO]
• CPC Class Codes: C01B 2203/0288 containing two CO-shift steps
• CPC Class Codes: C01B 2203/0294 containing three or more 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 2203/066 with fuel cells
• 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 2203/147 : Three or more purification steps in series
• CPC Class Codes: C01B 2203/1604 : Starting up the process
• CPC Class Codes: C01B 2203/82 : Several process steps of C01B2203/02 - C01B2203/08 integrated into a single apparatus
• CPC Class Codes: C01B 3/382 : Multi-step processes
• CPC Class Codes: C01B 3/386 : Catalytic partial combustion
• CPC Class Codes: C01B 3/48 : followed by reaction of water vapour with carbon monoxide
• CPC Class Codes: C01B 3/583 : the reaction being the selective oxidation of carbon monoxide
• 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

Abstract

An improved fuel processor for fuel cells is provided whereby the startup time of the processor is less than sixty seconds and can be as low as 30 seconds, if not less. A rapid startup time is achieved by either igniting or allowing a small mixture of air and fuel to react over and warm up the catalyst of an autothermal reformer (ATR). The ATR then produces combustible gases to be subsequently oxidized on and simultaneously warm up water-gas shift zone catalysts. After normal operating temperature has been achieved, the proportion of air included with the fuel is greatly diminished.

Claims

1. A fuel processor comprising:

a. a housing containing a nozzle, whereby the nozzle is adapted to mix fuel and air within the confines of the nozzle;

b. a heating surface adapted to heat and oxidize the mixed fuel;

c. a reforming catalyst, whereby the fuel heating surface is positioned intermediate said nozzle and catalyst, and comprises passageways for the heat and heated fuel to pass through to contact the catalyst;

d. water-gas reaction zones positioned downstream from said reforming catalyst;

e. a heat exchanger positioned up stream of each water gas reaction zone; and

f. mixing zones present between said water-gas reaction zones and said heat exchangers wherein the mixing zones provide a means to mix air with reformate gas generated in said water-gas reaction zones.

2. A fuel processor as recited in claim 1 wherein the fuel heating surface is comprised of coils arranged in a configuration defining a plane positioned perpendicularly to the direction of flow of fuel through the housing.

3. The fuel processor as recited in claim 1 wherein the nozzle is adapted to homogeneously mix liquid fuel and cold air.

4. The fuel processor as recited in claim 1 wherein the nozzle is adapted to homogeneously mix vaporized fuel, heated air, and superheated steam.