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