1330 microlith fuel reforming and fuel processing systems ... · atr steam generator hex, sulfur...

Anthony AndersonDirector, Marketing & Business Development

2013 Hannover Messe Group Exhibit Hydrogen + Fuel Cells

April 11, 2013

Microlith® Fuel Reformer and Fuel Processor Systems

2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013

• Technologies : Microlith® Catalytic Reactors, RCL® Combustors Reforming: Syngas, H2, Chemicals, kW – MW scales

Sorption: Bio/Chem, Sulfur, trace contaminants Small engines: Tactical Power, UAV Combustion: Gas turbines, burners, augmentation, down-hole, Stirling Prototypes: BOP, Controls, packaging

• Established 1986; Privately held, Small Business; 39 employees; North Haven, CT

• Collaborators include: U.S. Govt., large & small corporations, universities, national labs.

• Develop advanced catalysts, reactors/systems; manufacture limited-volume prototypes

Precision Combustion, Inc.

38,000 sq ft facility

2


PCI Technology-Product-Application Space

Power

Fuel CellsAPUs/gensetVehicle/Ship

IC EnginesTactical Gensets

UXV Fuel Cells

Reformers for Industrial Systems

Combustion

Kitchen Burner

Stirling Burner

Fuel Cell Oxidizers

Catalytic Combustors

• Combustors• Steam generators

Air Cleaning

Oxidizers

Adsorbers

Other

H2 generation/ compact GTL

Catalytic ignitors

Chemicals manufacture

3


Microlith® Reactor Technology

Small, durable, catalytically coated metal mesh with very high surface area

PCI holds multiple patents on catalyst structure, reaction methods and apparatus

Continuous catalyst coating line with batched furnace and rigorous QA, QC in place

Microlith® Catalytic ReactorsUltra compact

Short contact timeRapid thermal response

High heat & mass transferHigh surface area/unit volume

Low cost

4


Microlith® Reactor Technology

Cells/in2

GSA (m 2/l)Channel Length (in)

Length to Diameter Ratio (L/d)Operating Temperature ( oC)

Frontal Open Area

4002.64

3.0 - 5.070 - 120

1050 - 120070

25006.3

0.0030.3

1050 - 120072

Microlith®Conventional Monolith

Monolith wall

Monolith wall

Monolith wall

Boundary layer formation

Mixing regions

Boundary layer formation

High surface area & high mass/high heat transfer capability at comparable pressure drop

5


6

Comparison of Substrate Performance (Steady State Operation w. propylene in air at 350 C, vel. 1.5 m/s.)

2.54 cm(1”) long monolith 7 Microlith elements(Length = 0.11cm, 0.042”)

5.3 cm/s7620 cm2

75

77 cm/s568 cm2

78

Equivalent conversion with 20-fold size reduction.

More Efficient Use of Catalyst Surface Area

Mass Transfer Coeff (kc)GSA

Observed Conversion (%)


7

Rapid Thermal Response

0

100

200

300

400

0 2 4 6 8 10 12 14

Tem

pera

ture

(C)

Time (sec)

MonolithMicrolith®

• Lumped Capacitance Analysis (const. temp. fluid)• No contribution due to exothermic reactions• tc = mCp/hAt Microlith® = 0.12 sec; Monolith = 3.4 sec.

Fast Transient Response


8

Benefits of Improved Mass Transfer

500

700

900

1100

1300

1500

1700

1900

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Selectivity

T ad

iaba

tic, C

TD analysis, f = 3.5, T inlet = 527oC

CH4 + 2 O2 CO2 + 2 H2O -192 kcal/m

CH4 + ½ O2 CO + 2H2 -8.5 kcal/m

0

5

10

15

20

25

30

35

40

0 1 2 3 4 5

axial position, mm

conc

entr

atio

n, %

700

750

800

850

900

950

1000

1050

1100

tem

pera

ture

, C

H2 O2CH4 COCO2 H2OT catalyst

phi v,m/s T max,C H2% CO% H2O% CO2% CH4% conv% H2_sel% CO_sel%3.4 2.6 1075 36.43 18.22 2.34 1.17 0.06 99.67 93.96 93.96

CH4 CPOX; Experimental Data


9

Reforming (for Fuel Cells, H2 gen, Comb. Aug.)

1. Catalytic Partial Oxidation (CPOX)2 CH4 + O2 4 H2 + 2CO {H2O + CO2 - ∆H}

2. Catalytic Autothermal Reforming (ATR)

3 CH4 + O2 + H2O 7 H2 + 3 CO {H2O + CO2 - ∆H}

3. Catalytic Steam Reforming (CSR)

CH4 + H2O 3 H2 + CO {H2O + CO2 + ∆H}

PCI has ongoing programs in all these areas, using its Microlith® Technology

5 kWth DieselFor Automotive

5 MWth Nat. Gas

Fuel + Steam (CSR Inlet)

H2, CO

Fuel + Air (CTOX Inlet)

H2O, CO2

5 kWth & 1 MWth Diesel/JP-8 ATR, St. gen. S-trap, Injector

3 - 10 kWth Diesel/JP-8 SR, St. gen, Exo/Endo, Hi P.


10

H2 Purification

• Water Gas Shift Reactor (WGSR)CO + H2O H2 + CO2 {CH4 - ∆H}

• Preferential Oxidation of CO (PROX)CO + ½ O2 {H2} CO2 {H2O - ∆H}

• Membrane Separation IntegrationPd/Ag/Polymer on metal/ceramic supports

• Pressure Swing Adsorption (PSA)H2 selective sorbents

PCI has ongoing programs in these areas


Commercial Applications

Aircraft APU Truck APU Marine APU

Fuel Cell Range Extenders RV APU Industrial Syngas

11


PCI innovation: Sulfur-tolerant Logistics Fuel Reformer

• Ultra-compact high efficiency reformer able to convert diesel, military fuels, alcohols, biofuels to sulfur-free syngas (H2+CO)

• Microlith design combination is uniquely compact, sulfur-tolerant and efficient

• Value added: We put the fuel in fuel cells®

– PCI reformer/fuel processing system allows SOFC fuel cells to use diesel/military fuels– With PCI WGS, allows HT-PEM fuel cells to use diesel/military fuels – With H2 separation technology, can produce high quality hydrogen from diesel/military fuels

12


Compared to other fuel processors, our solution offers

• Lower weight up to 3X!

• Smaller size up to 6X!

• Faster response • Lower pressure drop• Significantly reduced cost

Comparison with Other Options

13


Capable of Startup, load following, shutdown

PCI Designs/Supports Complete SOFC Integrated Systems

Fuel Processor

(ATR, injector, steam generator,

sulfur trap, igniter, fuel & water pump,

air blower, fuel/air/water

control)

SOFC

(Stack, cathode air blower,Power conditioning,

stack controller,AGB)

Reformate Flow

Control

Thermal balance

é

Fuel, Air, Water

14


15

Reformer for 1 kWe SOFC Generator

5.5"

3.5"

• Reformer includes reforming catalyst, steam generator HEX, startup glow plug, & sulfur cleanup• Capable of producing SOFC-quality reformate from up to 3000 ppm S JP-8• Operates under water neutral conditions (low steam-to-carbon ratio) with logistic fuels & diesels


Reformer Subsystem + BOP

• 40 kWth reformer: weight ~17 kg (Reformer + Mixer/injector + Sulfur Trap) • Steady state parasitic power needs for 1-2 kWe: <100 We

16


5.0

5.3

6.4

5.6

17.3

ATR

Sulfur Trap

WGSR 5.3

6.4

5.6

17.3

6.6

5.3

6.4

5.6

17.3

ATR

Sulfur Trap

WGSR

25 kWth ATR w. fuel/air/steam injector, igniter, steam generating HX, sulfur trap, WGSR

Fuel Processor (HT-PEM/PEM)

17


18

ATR Reformate Compositions(mole %, wet basis)

ATR HEX Sulfur TrapF/A/SAtomizer

• Reforming efficiency (LHV reformate/LHV feed) = ~85%• Sulfur removal to <1 ppm• Current PCI’s target for coke precursors (i.e., C2s and C3s) is <50 ppmv total

WGSR

Fuel S/C O/C H2O H2 N2 CO CO2 CH4 C2 + C3 S

JP-8 (Equil) 0.90 0.95 12.1 29.5 37.5 15.3 5.7 0.01 -

JP-8 (Exptl) 0.90 0.95 12.7 28 37.7 16.3 5.4 0.16 <50 ppm <1 ppm

After WGSR 10-15 35 39 <1 * 12-14 0.3

[*: Fn of St/C]


ATR Scale-up: 1 MWth ATR System

Modular 250 kWe Fuel Processing System consisting of fuel/air/steam injector, ATR steam generator hex, sulfur clean-up, controls, pumps, blowers, filters,

sensors.

63”

48”

ATR

Igniter

SteamGenerator

Trim HEX

Desulf.

W GSR

Injector

63”

48”

ATR

Igniter

SteamGenerator

Trim HEX

Desulf.

W GSR

Injector

6.8

ft

19


1 MWth Microlith® Autothermal Reformer to reform VOC compounds from process waste streams

Scale-up: 1 MWth VOC Reformer

20


21

CPOX Scale-up: 5 MW(th) Natural Gas Processor

• Performance testing successfully completed.• 1000 hrs of sub-scale durability completed (Target 8000 hrs).

5 MWth reactor to reform natural gas to produce syngas


7 – 10 kWth CSR for Diesel, Natural Gas

• Low peak temperatures• Sulfur tolerance (~5 ppm)• High Heat Flux Compact size• Capable of high pressure operation• Achieves thermodynamic efficiency at Low S/C ratios

Catalytic burner instead of flame-stabilized burner increases thermal uniformity, distribution, durability & control.

22


Come See Us!

Precision Combustion, Inc.Booth# D76/1We put the fuel in fuel cells®

Tony AndersonDirector, Marketing & Business Development

[email protected]+1 203-287-3700 Ext.290

Kevin BurnsPresident

[email protected]+1 203-287-3700 Ext. 213

23

1330 microlith fuel reforming and fuel processing systems ... · atr steam generator hex, sulfur...

Documents