초록 ▼

A compact autothermal (partial oxidation and steam reforming) fuel reactor is provided for implementation with a fuel cell system. The reactor includes a premixing chamber for premixing a volume of air, steam and fuel into an effluent, a thermal POX reactor, a first stage reforming segment, a post-p

A compact autothermal (partial oxidation and steam reforming) fuel reactor is provided for implementation with a fuel cell system. The reactor includes a premixing chamber for premixing a volume of air, steam and fuel into an effluent, a thermal POX reactor, a first stage reforming segment, a post-premix chamber, and a second stage reforming segment. Further provided are a water/fuel vaporizer for supplying steam and fuel as a gas to the premix chamber and an airflow cavity disposed about the reactor for pre-heating air supplied to the premix chamber. The thermal POX segment operates during an initial start-up period for pre-heating the other components of the reactor. Once the other components achieve an operation temperature, the first and second stage reforming segments catalytically reform the effluent. The premix and post-premix chambers enable variance in the O/C and S/C ratios to be achieved as the effluent is reformed through the multiple stages.

대표청구항 ▼

1. A method of operating an autothermal reactor for reforming a hydrocarbon fuel into a hydrogen-rich reformate stream, comprising the steps of:operating a thermal partial oxidation reactor of the autothermal reactor for a first period for thermally reforming the fuel and generating heat; heating co

1. A method of operating an autothermal reactor for reforming a hydrocarbon fuel into a hydrogen-rich reformate stream, comprising the steps of:operating a thermal partial oxidation reactor of the autothermal reactor for a first period for thermally reforming the fuel and generating heat; heating components of the autothermal reactor during said first period; switching to a second period after said components achieve an operational temperature; premixing the hydrocarbon fuel stream with at least one of air and steam for producing a mixed reactant stream; reforming said mixed reactant stream in a first stage catalytic reformer of the autothermal reactor for producing an effluent stream; reforming said effluent stream in a second stage catalytic reformer of the auto-thermal reactor for producing the reformate stream; and simultaneously transferring heat between components of the autothermal reactor for maintaining operational temperatures thereof during said second period. 2. The method of claim 1, further comprising the step of post-premixing said effluent stream with at least one of air, fuel and steam prior to reformation in said second stage catalytic reformer.3. The method of claim 1, further comprising the steps of providing a catalytic partial oxidization section and a catalytic steam reforming section for comprising said first stage reformer.4. The method of claim 1, further comprising the steps of providing a catalytic partial oxidization section and a catalytic steam reforming section for comprising said second stage reformer.5. The method of claim 1, further comprising the steps of:providing an outer shell having a passage therethrough that is in heat exchange communication with said components of the autothermal reactor; preheating air flowing through said passage with heat generated during either of said first and second periods. 6. The method of claim 1, further comprising the steps of:providing a vaporizer in heat exchange communication with the reformate stream exiting said second stage reformer; heating said vaporizer with heat from the reformate stream; and vaporizing at least one of fuel and water within said vaporizer to be supplied to the autothermal reactor. 7. The method of claim 6, wherein said vaporizer is further in heat exchange communication with said thermal partial oxidation reactor and the reformate stream.8. The method of claim 1, comprising the step of providing a premix chamber for premixing the hydrocarbon fuel stream with at least one of air and steam for producing said mixed reactant stream.9. The method of claim 8, further comprising the steps of:providing a mixing chamber in fluid communication with an air source; providing a plurality of radially disposed fuel vapor injectors in fluid communication with said mixing chamber; providing a plurality of radially disposed steam injectors in fluid communication with said mixing chamber; and providing a grid disposed within said mixing chamber having a plurality of premix injection holes. 10. The method of claim 1, wherein said mixed reactant stream has a first oxygen to carbon ratio and said effluent stream has a second oxygen to carbon ratio.11. The method of claim 1, wherein the mixed reactant stream has a first steam to carbon ratio and said effluent stream has a second steam to carbon ratio.12. An autothermal reactor for reforming a hydrocarbon fuel stream into a hydrogen-rich reformate stream, the autothermal reactor comprising:a premix chamber for mixing the hydrocarbon fuel stream with at least one of air and steam for producing a mixed reactant stream; a first stage catalytic reformer for partially reforming said mixed reactant stream into an effluent stream, said first stage catalytic reformer in fluid communication with an outlet of said premix chamber; a post-premix chamber for mixing said effluent stream with at least one of air, steam and fuel vapor, said post-premix chamber in fluid communication with an outlet of said first stage catalytic reformer; and a second stage catalytic reformer for further reforming said effluent stream to form the reformate stream, said second stage catalytic reformer in fluid communication with an outlet of said post-premix chamber and nested within said first stage catalytic reformer in heat exchange communication with said first stage catalytic reformer; and a thermal reactor for combusting the hydrocarbon fuel with air to form a combustion stream during a start-up period prior to supplying the hydrocarbon fuel stream and said at least one of air and steam to said premix chamber, said thermal reactor having an outlet for supplying said combustion stream to said first and second stage catalytic reformers for heating said first and second stage catalytic reformers to establish a normal operational temperature thereof. 13. The autothermal reactor of claim 12, wherein said first stage catalytic reformer comprises one of a catalytic partial oxidization section and a catalytic steam reforming section.14. The autothermal reactor of claim 12, wherein said second stage catalytic reformer comprises one of a catalytic partial oxidization section and a catalytic steam reforming section.15. The autothermal reactor of claim 12, wherein endothermic components of said first stage catalytic reformer are in heat exchange relation with exothermic components of said second stage catalytic reformer.16. The autothermal reactor of claim 12, wherein endothermic components of said second stage catalytic reformer are in heat exchange relation with exothermic components of said first stage catalytic reformer.17. The autothermal reactor of claim 12, further comprising a vaporizer in fluid communication with said premix chamber and heat exchange communication with said reformate stream exiting said second stage catalytic reformer, whereby heat from said reformate stream enables said vaporizer to vaporize at least one of said fuel and water to be supplied to said premix chamber.18. The autothermal reactor of claim 12, further comprising a transient temperature control element disposed between said thermal reformer and said first stage catalytic reformer.19. An autothermal reactor for reforming a hydrocarbon fuel stream into a hydrogen-rich reformate stream, the autothermal reactor comprising:a premix chamber for mixing the hydrocarbon fuel stream with at least one of air and steam for producing a mixed reactant stream; a first stage catalytic reformer for partially reforming said mixed reactant stream into an effluent stream, said first stage catalytic reformer in fluid communication with an outlet of said premix chamber; a post-premix chamber for mixing said effluent stream with at least one of air, steam and fuel vapor, said post-premix chamber in fluid communication with an outlet of said first stage catalytic reformer; a second stage catalytic reformer for further reforming said effluent stream to form the reformate stream, said second stage catalytic reformer in fluid communication with an outlet of said post-premix chamber and in heat exchange communication with said first stage catalytic reformer; a thermal reactor for combusting the hydrocarbon fuel with air to form a combustion stream during a start-up period prior to supplying the hydrocarbon fuel stream and said at least one of air and steam to said premix chamber, said thermal reactor having an outlet for supplying said combustion stream to said first and second stage catalytic reformers for heating said first and second stage catalytic reformers to establish a normal operational temperature thereof; and an outer shell having a passage therethrough that is in fluid communication with said premix chamber and in heat exchange communication with other components of the autothermal reactor. 20. The autothermal reactor of claim 19, wherein a flow of air travels through said passage whereby said air is preheated prior to entering said premix chamber.21. An autothermal reactor for reforming a hydrocarbon fuel stream into a hydrogen-rich reformate stream, the autothermal reactor comprising:a premix chamber for mixing the hydrocarbon fuel stream with at least one of air and steam for producing a mixed reactant stream wherein said premix chamber includes a mixing chamber in fluid communication with an air source, a plurality of radially disposed fuel vapor injectors in fluid communication with said mixing chamber, a plurality of radially disposed steam injectors in fluid communication with said mixing chamber, a grid disposed within said mixing chamber having a plurality of premix injection holes, whereby air flows through said grid to mix with fuel and steam provided by said injectors for producing said first effluent; a first stage catalytic reformer for partially reforming said mixed reactant stream into an effluent stream, said first stage catalytic reformer in fluid communication with an outlet of said premix chamber; a post-premix chamber for mixing said effluent stream with at least one of air, steam and fuel vapor, said post-premix chamber in fluid communication with an outlet of said first stage catalytic reformer; a second stage catalytic reformer for further reforming said effluent stream to form the reformate stream, said second stage catalytic reformer in fluid communication with an outlet of said post-premix chamber and in heat exchange communication with said first stage catalytic reformer; a thermal reactor for combusting the hydrocarbon fuel with air to form a combustion stream during a start-up period prior to supplying the hydrocarbon fuel stream and said at least one of air and steam to said premix chamber, said thermal reactor having an outlet for supplying said combustion stream to said first and second stage catalytic reformers for heating said first and second stage catalytic reformers to establish a normal operational temperature thereof. 22. The autothermal reactor of claim 21, further comprising an outer shell having a passage therethrough, in fluid communication with said premix chamber and in heat exchange communication with other components of the autothermal reactor, wherein a flow of air travels through said passage and is pre-heated prior to entering said premix chamber.23. The autothermal reactor of claim 21, further comprising a vaporizer in fluid communication with said premix chamber and heat exchange communication with said reformate stream exiting said second stage catalytic reformer, whereby heat from said reformate stream enables operation of said vaporizer to vaporize at least one of fuel and water to be supplied to said premix chamber through said fuel vapor and steam injectors.