atr performance for liquid fuel applications

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Autothermal Reformer (ATR) Performance for

Liquid Fuel (Bio-fuel to Diesel) Applications

2008 Advanced Energy Conference

Hauppauge, NY

November 19th, 2008

Dean Modroukas, PhDDirector, Advanced Programs

ATK TP&CRonkonkoma, NY

Florin GirleaATK TP&C

Ronkonkoma, NY

Marco J. Castaldi, PhDEarth & Envtl. Eng Dept

Columbia UniversityNew York, NY

Federico BarraiEarth & Envtl. Eng Dept

Columbia UniversityNew York, NY

Robert J Farrauto, PhDBASF Catalysts, LLC

Iselin, NJ

Presented by:

Jason S. Tyll, PhDDeputy Director, Advanced Programs

ATK TP&C




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Background

• Fuel Reforming - The conversion of fuels into a hydrogen rich gas mixture (syngas)with the employment of catalytic reactors

• A Fuel Reformer can be built in a variety of configurations depending on therequired product quality.

• There are a wide range of conventional fuels that can be used in a fuel processor,such as:

– natural gas, propane, butane, light distillates, methanol, ethanol, propanol, dimethyl-

ether, naphtha, gasoline, diesel, biodiesel, naval distillate fuel, kerosene, and jet fuelsthat could be used in the reforming processes

nMethanatio molkJ206H 3HCO

ShiftGasWaterRev. mol

kJ2.14H C

OxidationH mol

kJ-242H 2

1H

OxidationCO mol

kJ-283H 2

1

242

222

2222

22

O H CH

O H CO H O

O H O

COOCO

AutothermalReforming

PreferentialOxidation

ShiftGasrWatemol

kJ41.2ΔH HCOOHCO

ReformingSteam mol

kJ1,694ΔH H2

2111COO11HHC

OxidationPartial mol

kJ-966.8ΔH 11H11COO2

11HC

222

222111

222111




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H2 32%41%

38%

CO 10%1%

10 ppm

CO2 11%20%

21%

H2O 25%16%

19%

CxHy

H2OO2

(balance N2)

Fuel Processors - Reactors

SOFC

300˚C

700˚C

280˚C

330˚C

120˚C

200˚C

80˚C

ProcessingOptions

Chemical

Process

Thermal

Process




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The concept of autothermal reforming implies that heat produced by exothermicreactions is used by endothermic reactions with the condition that the heatexchange occurs within the same process flow without being separated by a heattransfer barrier.

The obvious advantage is the simplicity of design and the absence of heat transferhardware, therefore a better thermal efficiency.

Autothermal Reforming Reactor (ATR)

Exhaust ports

Inlet ports

•Precious metal catalyst on alumina•kinetic volume: 240 cc•100 SLPM total flow•GHSV = 25,000 h-1




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Autothermal Reforming Reactor (ATR)

Features and Benefits:

• Incorporate integral heat exchanger into ATR structure in order to vaporize liquid fuel+H2Omixture (utilizing energy released at the catalytic wall) and control product temperature at ATRexit

• Ease of manufacturing (quick and inexpensive manufacturing process utilizing conventionalmachining)

• Line of sight to catalyst wall for easy catalyst application and subsequent inspection

• Minimize thermal mass of ATR reactor structure (for fast start-up) and minimize temperature

gradients across reactor height (structural and flowpath integrity implications)

• Design concept can be used to complete the fuel reforming process by allowing integrationwith desulfurization unit, WGS, and PROX reactors

• ATR reactor structural material compatibility with catalyst coat and steady-state operationalpeak temperature of 1,000ºC (1800ºF)




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Experimental Setup

ATR reactor sized for 2 kW fuel cell (2” x 7” x 23”)

• Stainless steel construction with integral inlet and exhaustplenums.

• Nitrogen pressurized tanks for fuel (JP-8) and water delivery.

• Electronic mass flow controller for air delivery, and highaccuracy rotometers for fuel and water delivery.

• Electric heaters utilized for water vaporization and air pre-heating.

• Novel liquid fuel injection into steam stream and subsequentmixing and vaporization.

• Heavily instrumented with 50 thermocouples (reactor centerline

and outboard) measuring catalytic wall and external surfacetemperatures. Additional ports available for gas chromatographymeasurements.

• Automated data acquisition provides real time reactormonitoring and data capture for subsequent analysis.




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ATR Temperature Profile – Wall Temperatures

Wall temperatures show initial region dominated by exothermic CPOXreaction followed by region dominated by endothermic steam reforming.

Additional testing required to optimize reactor length.




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• Catalyst light-off is preceded by complete

oxidation (as indicated by the presence of CO2and consumption of O2)

• Light-off takes place in the back-end of thecatalyst bed and propagates upstream to thefront-end.

• Syngas is detected only after light-off andpropagation.

• Constant temperatures in the fuel deliverysystem - fuel mix ignition prior to reactor(residence time of flammable mixture in the fueldelivery system is shorter than the ignition delaytime for JP-8)

H2

CO

CO2

O2

GC data [mol %]

ATR Test Data: Light-Off




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ATR Test Data: Conversion




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Future Work

• Measure olefin and higher HC production

• Assess reactor utilization

• Close thermal balance and calculate feasibility of heat integration

• Perform application specific durability testing

–Load following

– Catalyst deactivation




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Applications - Military

Small Scale Logistic Fuel Engines• Enables small scale IC engine operation

with military logistic fuels• Reduced weight, improved performance

Mobile Electric Power• Logistic fueled UAV engines

Portable Waste to Energy• Reform products of gasification (bio-oils,

methane, etc.)• Reformate suitable for burner, fuel cell,

or fuel synthesis

Mobile Electric Power• Fuel cell based generators, APU

• Reform military logistic fuels for direct usewith SOFC or further processing for PEM fuel cell

• Soldier Power, Portable Power, Mobile Electric Power




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Applications - Commercial

Biofuels Generation• Reform products of gasification (bio-oils,

methane, etc.)• Reformate suitable for fuel synthesis

Waste to Energy• Reform products of gasification

(bio-oils, methane, etc.)• Reform land fill gas (methane, etc.)• Reformate suitable for burner,

fuel cell, or fuel synthesis

Power Generation• Fuel cell based generators, APU• Reform diesel, natural gas, LPG, etc. for direct use with

SOFC or further processing for PEM fuel cell• Portable power, residential generator

atr performance for liquid fuel applications

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