Microlith Fuel Reformer and Fuel Processor Systems

Transcription

1 Microlith Fuel Reformer and Fuel Processor Systems Anthony Anderson Director, Marketing & Business Development

2 Precision Combustion, Inc. Technologies : Microlith Catalytic Reactors, RCL Combustors Reforming: Syngas, H 2, 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 2

3 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 Chemicals manufacture Reformers for Industrial Systems Catalytic Combustors Combustors Steam generators 3

4 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 4

5 Microlith Reactor Technology Conventional Monolith Microlith Cells/in 2 GSA (m 2 /l) Channel Length (in) Length to Diameter Ratio (L/d) Operating Temperature ( o C) Frontal Open Area Monolith wall Mixing regions Boundary layer formation Monolith wall Boundary layer formation Monolith wall 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, ) 5.3 cm/s 7620 cm 2 75 Mass Transfer Coeff (k c ) GSA Observed Conversion (%) 77 cm/s 568 cm 2 78 Equivalent conversion with 20-fold size reduction. More Efficient Use of Catalyst Surface Area 6

7 Rapid Thermal Response Lumped Capacitance Analysis (const. temp. fluid) No contribution due to exothermic reactions t c = mc p /ha t Microlith = 0.12 sec; Monolith = 3.4 sec. 400 Temperature (C) Time (sec) Monolith Microlith Fast Transient Response 7

8 Benefits of Improved Mass Transfer T adiabatic, C CH O 2 CO H 2 O -192 kcal/m CH 4 + ½ O 2 CO + 2H kcal/m concentration, % H2 CH4 CO2 T catalyst O2 CO H2O temperature, C Selectivity axial position, mm 700 TD analysis, f = 3.5, T inlet = 527 o C CH4 CPOX; Experimental Data phi v,m/s T max,c H2% CO% H 2 O% CO 2 % CH 4 % conv% H 2 _sel% CO_sel%

9 Reforming (for Fuel Cells, H 2 gen, Comb. Aug.) 1. Catalytic Partial Oxidation (CPOX) 2 CH 4 + O 2 4 H 2 + 2CO {H 2 O + CO 2 - H} 5 kwth Diesel For Automotive 5 MWth Nat. Gas 2. Catalytic Autothermal Reforming (ATR) 3 CH 4 + O 2 + H 2 O 7 H CO {H 2 O + CO 2 - H} 5 kwth & 1 MWth Diesel/JP-8 ATR, St. gen. S-trap, Injector 3. Catalytic Steam Reforming (CSR) H 2, CO Fuel + Air (CTOX Inlet) CH 4 + H 2 O 3 H 2 + CO {H 2 O + CO 2 + H} H 2 O, CO 2 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 9

10 H 2 Purification Water Gas Shift Reactor (WGSR) CO + H 2 O H 2 + CO 2 {CH 4 - H} Preferential Oxidation of CO (PROX) CO + ½ O 2 {H 2 } CO 2 {H 2 O - H} Membrane Separation Integration Pd/Ag/Polymer on metal/ceramic supports Pressure Swing Adsorption (PSA) H 2 selective sorbents PCI has ongoing programs in these areas 10

11 Commercial Applications Aircraft APU Truck APU Marine APU Fuel Cell Range Extenders RV APU Industrial Syngas 11

12 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

13 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 13

14 PCI Designs/Supports Complete SOFC Integrated Systems Capable of Startup, load following, shutdown é Fuel Processor (ATR, injector, steam generator, sulfur trap, igniter, fuel & water pump, air blower, fuel/air/water control) Reformate Flow Thermal balance Control SOFC (Stack, cathode air blower, Power conditioning, stack controller, AGB) Fuel, Air, Water 14

15 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" 15

16 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

17 Fuel Processor (HT-PEM/PEM) 6.6 ATR Sulfur Trap WGSR kw th ATR w. fuel/air/steam injector, igniter, steam generating HX, sulfur trap, WGSR 17

18 ATR Reformate Compositions (mole %, wet basis) F/A/S Atomizer ATR HEX Sulfur Trap WGSR Fuel S/C O/C H 2 O H 2 N 2 CO CO 2 CH 4 C2 + C3 S JP-8 (Equil) JP-8 (Exptl) <50 ppm <1 ppm After WGSR <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 ppm v total 18

19 ATR Scale-up: 1 MW th ATR System Injector 63 ATR Igniter St eam Generator 6.8 ft Trim HEX WGSR Desulf. 48 Modular 250 kw e Fuel Processing System consisting of fuel/air/steam injector, ATR steam generator hex, sulfur clean-up, controls, pumps, blowers, filters, sensors. 19

20 Scale-up: 1 MWth VOC Reformer 1 MWth Microlith Autothermal Reformer to reform VOC compounds from process waste streams 20

21 CPOX Scale-up: 5 MW(th) Natural Gas Processor 5 MWth reactor to reform natural gas to produce syngas Performance testing successfully completed hrs of sub-scale durability completed (Target 8000 hrs). 21

22 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

23 Come See Us! Precision Combustion, Inc. Booth# D76/1 We put the fuel in fuel cells Tony Anderson Director, Marketing & Business Development Ext.290 Kevin Burns President Ext