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Autothermal Reformer (ATR) Performance for Liquid Fuel (Bio-fuel to Diesel) Applications
Presented by: Jason S. Tyll, PhD Deputy Director, Advanced Programs ATK TP&C

2008 Advanced Energy Conference Hauppauge, NY November 19th, 2008

Dean Modroukas, PhD Director, Advanced Programs ATK TP&C Ronkonkoma, NY

Florin Girlea ATK TP&C Ronkonkoma, NY

Marco J. Castaldi, PhD Earth & Envtl. Eng Dept Columbia University New York, NY

Federico Barrai Earth & Envtl. Eng Dept Columbia University New York, NY

Robert J Farrauto, PhD BASF Catalysts, LLC Iselin, NJ

Background
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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 the required 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, dimethylether, naphtha, gasoline, diesel, biodiesel, naval distillate fuel, kerosene, and jet fuels that could be used in the reforming processes
C 11 H 21 11 2 O 2 11CO 11H 21 2 H -966.8 kJ H 1,694 kJ H 41.2 kJ Partial Oxidation

mol

C 11 H 21 11H 2 O 11CO CO H 2 O CO
2

H2

mol mol

Steam Reforming Wate r Gas Shift

H2

Autothermal Reforming

CO H2

1 2 1 2

O 2 CO 2 O 2 H 2O

H -283 kJ H -242 kJ H 4 1 . 2 kJ

mol mol mol mol

CO Oxidation H 2 Oxidation Rev. Water Gas Shift Methanatio n

C O 2 H 2 CO H 2 O CO 3H
2
2

Preferential Oxidation

CH

H 2O

H 206 kJ

Fuel Processors - Reactors

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SOFC

Processing Options

41%

H2

32%
10% 1% 20% 16%

38%
10 ppm 21% 19%
(balance N2)

CxHy H2O O2

CO

Chemical Process

CO2 H2O

11% 25%

700C 330C 300C

3

200C 280C 120C 80C

Thermal Process

Autothermal Reforming Reactor (ATR)

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The concept of autothermal reforming implies that heat produced by exothermic reactions is used by endothermic reactions with the condition that the heat exchange occurs within the same process flow without being separated by a heat transfer barrier. The obvious advantage is the simplicity of design and the absence of heat transfer hardware, therefore a better thermal efficiency.
Precious metal kinetic volume:

catalyst on alumina 240 cc 100 SLPM total flow GHSV = 25,000 h-1

Inlet ports

Exhaust ports
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Autothermal Reforming Reactor (ATR)

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Features and Benefits: Incorporate integral heat exchanger into ATR structure in order to vaporize liquid fuel+H2O mixture (utilizing energy released at the catalytic wall) and control product temperature at ATR exit Ease of manufacturing (quick and inexpensive manufacturing process utilizing conventional machining) 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 integration with desulfurization unit, WGS, and PROX reactors ATR reactor structural material compatibility with catalyst coat and steady-state operational peak temperature of 1,000C (1800F)

Experimental Setup
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ATR reactor sized for 2 kW fuel cell (2 x 7 x 23) Stainless steel construction with integral inlet and exhaust plenums. Nitrogen pressurized tanks for fuel (JP-8) and water delivery. Electronic mass flow controller for air delivery, and high accuracy rotometers for fuel and water delivery. Electric heaters utilized for water vaporization and air preheating.

Novel liquid fuel injection into steam stream and subsequent mixing and vaporization.
Heavily instrumented with 50 thermocouples (reactor centerline and outboard) measuring catalytic wall and external surface temperatures. Additional ports available for gas chromatography measurements. Automated data acquisition provides real time reactor monitoring and data capture for subsequent analysis.

ATR Temperature Profile Wall Temperatures

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Wall temperatures show initial region dominated by exothermic CPOX reaction followed by region dominated by endothermic steam reforming. Additional testing required to optimize reactor length.
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ATR Test Data: Light-Off

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GC data [mol %]

Catalyst light-off is preceded by complete oxidation (as indicated by the presence of CO2 and consumption of O2) Light-off takes place in the back-end of the catalyst bed and propagates upstream to the front-end. Syngas is detected only after light-off and propagation. Constant temperatures in the fuel delivery system - fuel mix ignition prior to reactor (residence time of flammable mixture in the fuel delivery system is shorter than the ignition delay time for JP-8)

O2

CO2

CO

H2

8
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ATR Test Data: Conversion

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Future Work
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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
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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 use with SOFC or further processing for PEM fuel cell Soldier Power, Portable Power, Mobile Electric Power

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Applications - Commercial
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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
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