Microlith® Fuel Reformer and Fuel Processor Systems

Transcription

Microlith® Fuel Reformer and Fuel Processor Systems
Anthony Anderson
Director, Marketing & Business Development
2013 Hannover Messe Group Exhibit Hydrogen + Fuel Cells
April 11, 2013
Precision Combustion,
Inc.
•
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
38,000 sq ft facility
•
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
April 11, 2013
2
PCI Technology-Product-Application Space
Power
Combustion
Air Cleaning
Other
Fuel Cells
APUs/genset
Vehicle/Ship
Kitchen Burner
Oxidizers
H2 generation/
compact GTL
IC Engines
Tactical
Gensets
Stirling Burner
Adsorbers
Catalytic
ignitors
UXV
Fuel Cells
Fuel Cell
Oxidizers
Reformers for
Industrial
Systems
Chemicals
manufacture
Catalytic
Combustors
• Combustors
• Steam
generators
April 11, 2013
3
Microlith® Reactor Technology
Small, durable, catalytically coated metal mesh with
very high surface area
Microlith® Catalytic Reactors
Ultra compact
Short contact time
Rapid thermal response
High heat & mass transfer
High surface area/unit volume
Low cost
Continuous catalyst coating line with batched furnace
and rigorous QA, QC in place
PCI holds multiple patents on catalyst structure, reaction methods and apparatus
April 11, 2013
4
Microlith® Reactor Technology
Microlith®
Conventional Monolith
400
2.64
3.0 - 5.0
70 - 120
1050 - 1200
70
Cells/in 2
GSA (m 2/l)
Channel Length (in)
Length to Diameter Ratio (L/d)
Operating Temperature ( oC)
Frontal Open Area
2500
6.3
0.003
0.3
1050 - 1200
72
Mixing regions
Monolith wall
Boundary layer formation
Monolith wall
Boundary layer formation
Monolith wall
High surface area & high mass/high heat transfer capability at comparable pressure drop
April 11, 2013
5
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
5.3 cm/s
7620 cm2
75
7 Microlith elements
(Length = 0.11cm, 0.042”)
Mass Transfer Coeff (kc)
GSA
Observed Conversion (%)
77 cm/s
568 cm2
78
Equivalent conversion with 20-fold size reduction.
More Efficient Use of Catalyst Surface Area
April 11, 2013
6
Rapid Thermal Response
• Lumped Capacitance Analysis (const. temp. fluid)
• No contribution due to exothermic reactions
• tc = mCp/hAt Microlith® = 0.12 sec; Monolith = 3.4 sec.
Temperature (C)
400
300
200
Monolith
Microlith®
100
0
0
2
4
6
8
10
12
14
Time (sec)
Fast Transient Response
April 11, 2013
7
1900
40
1100
1700
35
1050
1500
30
1300
1100
CH4 + 2 O2  CO2 + 2 H2O -192 kcal/m
900
CH4 + ½ O2  CO + 2H2
700
-8.5 kcal/m
25
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
T max,C
1075
CO
CO2
H2O
1000
950
900
15
850
10
800
5
750
0
1
700
0
1
2
3
4
5
axial position, mm
CH4 CPOX; Experimental Data
TD analysis, f = 3.5, T inlet = 527oC
v,m/s
2.6
CH4
20
Selectivity
phi
3.4
O2
T catalyst
500
0
H2
temperature, C
concentration, %
T adiabatic, C
Benefits of Improved Mass Transfer
H2%
36.43
CO%
18.22
H2O%
2.34
CO2%
1.17
CH4%
0.06
April 11, 2013
conv%
99.67
H2_sel%
93.96
CO_sel%
93.96
8
Reforming (for Fuel Cells, H2 gen, Comb. Aug.)
1.
Catalytic Partial Oxidation (CPOX)
2 CH4 + O2  4 H2 + 2CO {H2O + CO2 - ∆H}
5 kWth Diesel
For Automotive
2.
5 MWth Nat. Gas
Catalytic Autothermal Reforming (ATR)
3 CH4 + O2 + H2O  7 H2 + 3 CO {H2O + CO2 - ∆H}
5 kWth & 1 MWth Diesel/JP-8 ATR, St. gen. S-trap,
Injector
3.
Catalytic Steam Reforming (CSR)
H2,
CO
CH4 + H2O  3 H2 + CO {H2O + CO2 + ∆H}
Fuel + Air
(CTOX
Inlet)
H2O,
CO2
Fuel + Steam
(CSR Inlet)
3 - 10 kWth Diesel/JP-8 SR, St. gen, Exo/Endo, Hi P.
PCI has ongoing programs in all these areas, using its Microlith® Technology
April 11, 2013
9
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 Integration
Pd/Ag/Polymer on metal/ceramic supports
• Pressure Swing Adsorption (PSA)
H2 selective sorbents
PCI has ongoing programs in these areas
April 11, 2013
10
Commercial Applications
Aircraft APU
Fuel Cell Range Extenders
Truck APU
RV APU
April 11, 2013
Marine 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
April 11, 2013
12
Comparison with Other Options
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
April 11, 2013
13
PCI Designs/Supports Complete SOFC Integrated
Systems
é
Capable of Startup, load following, shutdown
Fuel Processor
(ATR, injector,
steam generator,
sulfur trap, igniter,
fuel & water pump,
air blower,
fuel/air/water
control)
SOFC
Reformate Flow
Thermal balance
Control
(Stack,
cathode air blower,
Power conditioning,
stack controller,
AGB)
Fuel, Air, Water
April 11, 2013
14
Reformer for 1 kWe SOFC Generator
• 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
5.5"
3.5"
April 11, 2013
15
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
April 11, 2013
16
Fuel Processor (HT-PEM/PEM)
6.6
6.4
ATR
17.3
Sulfur Trap
5.6
WGSR
5.3
 5.0
25 kWth ATR w. fuel/air/steam injector, igniter, steam generating HX, sulfur trap, WGSR
April 11, 2013
17
ATR Reformate Compositions
(mole %, wet basis)
F/A/S
Atomizer
Fuel
S/C
JP-8 (Equil)
0.90
JP-8 (Exptl)
ppm
0.90
After WGSR
ATR
O/C
H2O
H2
N2
0.95 12.1
29.5
0.95 12.7
10-15
CO
WGSR
Sulfur Trap
HEX
CO2
CH4
C2 + C3
37.5 15.3
5.7
0.01
-
28
37.7 16.3
5.4
0.16
35
39
12-14 0.3
<1 *
S
<50 ppm
<1
[*: Fn of St/C]
• 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
April 11, 2013
18
ATR Scale-up: 1 MWth ATR System
Injector
63”
6.8 ft
A TR
I gnit er
St eam
Generat or
Trim HEX
W GSR
Desulf.
48”
Modular 250 kWe Fuel Processing System consisting of fuel/air/steam injector,
ATR steam generator hex, sulfur clean-up, controls, pumps, blowers, filters,
sensors.
April 11, 2013
19
Scale-up: 1 MWth VOC Reformer
1 MWth Microlith® Autothermal Reformer to reform VOC
compounds from process waste streams
April 11, 2013
20
CPOX Scale-up: 5 MW(th) Natural Gas Processor
5 MWth reactor to reform natural gas to produce syngas
• Performance testing successfully completed.
• 1000 hrs of sub-scale durability completed (Target 8000 hrs).
April 11, 2013
21
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.
April 11, 2013
22
Come See Us!
Precision Combustion, Inc.
Booth# D76/1
We put the fuel in fuel cells®
Tony Anderson
Director, Marketing & Business Development
[email protected]
+1 203-287-3700 Ext.290
Kevin Burns
President
[email protected]
+1 203-287-3700 Ext. 213
April 11, 2013
23

Microlith® Fuel Reformer and Fuel Processor Systems

Transcription

Similar documents