PDM_3_workshop_PCI_presentation_Roychoudhury_Rev_05.ppt
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ONR Workshop ◊ Aug 2008
Fuel Reforming & SOFC interface
- Lessons Learned August 11, 2008 Subir Roychoudhury
| Established in 1986, 30 employees; Located in North Haven, CT |
| Develops advanced catalytic reactors & systems; manufactures limited-volume catalytic products |
| Two major platform technologies under development |
| RCL® catalytic combustors for gas turbines and downhole applications |
| Microlith® catalytic reactors for multiple markets |
Precision Combustion, Inc.
PCI is in its 21st year and is focused on developing and manufacturing advanced catalytic reactors and systems.
PCI has 29 employees with background with a variety of defense contractors/Fortune 500 Companies as well as small start-ups in the fuel processing and gas turbine and portable power space.
PCI Technology Overview RCL® Catalytic Combustion
Microlith® Catalytic Reactors
| Best New Technology Award 2006 – IGTI, ASME |
| Full scale GT engine testing underway at OEM’s |
Ultra-compact Fuel Processing
ATR’s for liquid and gaseous fuels (e.g. JP-8, diesel) Reformers for SOFC, PEM & MCFC applications Waterless CPOX (e.g. Diesel, methane, propane) 50 - 250 kWe Fuel processing Systems Catalytic Burners
JP-8/Diesel/H2/anode gas burners 50 We – 50 kWe 35We-80We Stirling Engine Burners Regenerable Sorption Reactors:
Chem-bio filters Air revitalization for long-duration manned spaceflight
Place one GT picture in this slide.
FUEL CELL GENERATOR DESIGN APPROACH
Fuel Processor
(ATR, injector, steam generator, sulfur trap, igniter, fuel & water pump, air blower, fuel/air/water control)
SOFC
(Stack, cathode air blower, Power conditioning, stack controller, AGB)
Reformate Flow Control Thermal balance é Fuel, Air, Water
THERMAL, FLOW & CONTROL HANDSHAKES
Thermal
Start-up, shutdown Exhaust heat recovery Water recovery Temperature balancing (Reformate, cathode air) Flow
Reformate:
Quality Higher HC Sulfur
H2, CO
Flow rates (Transients) Control
Feedback protocols Diagnostic/corrective Synchronize response times Power conditioning Power management Hybridization User interface
| Reform sulfur containing fuels |
| Generate stack quality reformate |
| Sulfur cleanup |
| Avoid coke & soot precursors |
| Produce “Clean” H2 |
| Minimize water needs |
| Compact, lightweight & efficient |
| Low thermal & acoustic signature |
| Durability, reliability & maintainability |
| Manufacturability & cost |
LFP Challenges
DESIGN APPROACH & CHALLENGES
Fuel, Air Steam Water
ATR
HX
Sulfur Trap
HX
WGSR
To SOFC To H2 Cleanup/Separation, PEM
ASPEN® used to generate & optimize system design Operate @ low S:C for min. H2O in reformate Target O:C ratios to meet desired exit temp.
Steam generator HX design tightly bounded Material selection for high temp. operation Integrate effective sulfur cleanup approach Maximize thermal integration Minimize parasitic losses
Microlith® Compact Logistics Fuel Processor
| Liquid Fuel Processor ~5 kWthermal |
| 2 liters in volume includes fuel/air/steam injector, igniter, ATR, steam generator, sulfur trap |
| Targeted for genset and APU applications using PEM and solid oxide fuel cells |
LFP EMBODIMENT
Fuel in Ø 5.0” Water in Air in Reformate out 10.25” Fuel/Air/Steam injector Sulfur cleanup Mixing region Igniter
ATR
Steam generator
Fuel S:C O:C H2O H2 N2 CO CO2 CH4 C2 C3 S
JP-8 (Exptl) 0.95 0.9 12.7 28 37.7 16.3 5.4 0.16 0.02 0.00 0.005
JP-8 (Equil) 0.95 0.9 12.1 29.5 37.5 15.3 5.7 0.01 0 0 - REFORMATE COMPOSITION (Best Case Data vs. Equil - WET)
ATR
HX
ZnO F/A/S Atomizer Reforming efficiency (LHV reformate/LHV feed) = >80% Complete fuel conversion Fuel flow rate: 7 gms/min (~5 kWth) Reformate: 15.5 slpm H2; 9.2 slpm CO Fuel Specs: JP-8 w. 77 ppm sulfur
Room-temp Startup of Fuel Processor (air, fuel and water @ room temp);
Steady-State operation and Shutdown CPOX start; transition to steady state ATR (<10 min)
FUEL PROCESSOR OPERATION
ATR Startup in CPOX Mode
ATR START-UP
| Coking resistant |
| Control via PC interface |
| Size: 3 liters; Weight: 5.2 kg. |
| Operate at low S:C ratios (~1) |
| Reforming efficiency: >80% |
| 12 V battery for startup & controls |
| Cold to ATR steady state <10 minutes |
| Stand-alone BOP components being implemented |
| ATR durability: 1100 hrs w/o failure |
| Readily integrated w. SOFC, PEM, H2 generation systems |
| Modular (Injector, ATR, igniter, St. Gen. HX, sulfur trap) |
5 kWth FUEL PROCESSOR METRICS 5 -10 kWth LFP to convert JP-8*/Diesel+ into sulfur free (<1 ppm) reformate for 1 - 3 kWe SOFC
* 80 ppm sulfur; + Tier 2
Catalyst resistant to significant carbon deposition
SOFC STACK TESTING
Curt Reformer Hot box containing stack Umbilical connecting reformer to stack
SOFC STACK TESTING
| The reformer was run on low sulfur JP-8 |
| It was used to fuel a 60 cell bundle in Stack Tester. |
| • | The startup for the reformer, from cold to reformate availability, was < 10 min |
| • | Reformer operated at JP-8 flows of 3 g/min - 6.9 g/min (nominally 9.4– 21.6 SLPM H2 equiv.) |
| At S/C <1 and O (from air)/C <1. | |
| This should be sufficient fuel for at least a 2 kW DC fuel cell |
| • | Conversion was 100% and independent of reactant flow rate. |
| Main products were CO, CO2, H2, N2, H2O, w. traces of C2-C3 compounds. |
Operated with 1 kW SOFC stack – Stable Operation w/o coking ATR DURABILITY (1100 hrs)
Higher HC Formation
JP8 Fuel Cell Results
| 1102 hours total testing- 370hrs longest steady-state period |
| 6 thermal cycles |
| 1100kW-hr produced |
| DC Gross efficiency of 34% was achieved |
| Maximum power of 1.5kWe was obtained |
| Successful startup/operation/shutdown without purge was demonstrated |
| Successfully tested manual load-following (order of seconds) capabilities of system |
| No fuel cell performance difference beyond expected compositional changes observed |
| On shutdown and inspection, no carbon was found and no deleterious effects to the stack were observed |
Shipboard Fuel Processors
Acknowledgements
We are grateful to the DoD for supporting this program from concept through demonstration.
We thank, among others, ONR, ARL, TARDEC, CERDEC and AFRL for their support.
This work was done by the dedicated group of engineers and technicians at PCI who are key to the progress.
File details come from the government source that posted it. Updated .