United Technologies Corporation

International Fuel Cells, LLC

Utc Fuel Cells, LLC

Herbert J Setzer

Roger R Lesieur

John A Bett

Sam Karavolis

John C Trocciola

Paul R Margiott

Glenn W Scheffler

Raymond W Vine

Robert J Misage

Edmund K Parenti, Jr

Wayne G Wnuck

Donald R McVay

James R Hawkins

Warren R Standley

Roger R Leisieur

A fuel gas reformer assembly for use in a fuel cell power plant includes fuel gas passages, some of which contain a particulate alumina packing in which a vaporized steam-hydrocarbon fuel stream mixture is heated. The walls of the fuel gas passages are provided with an alumina coating which protects the walls of the passages from corrosion. The alumina coating of the walls, and alumina packing are both overlain by an alkaline earth metal oxide layer, such as a calcium oxide layer, that acts to limit carbon build-up on the surfaces of the coated passage walls. Limiting of carbon build-up in the reformer passages prevents premature clogging of the passages. The carbon build-up-limiting layer is formed on components of the reformer passages by applying a water-based slurry of alkaline earth metal compounds to the reformer passage surfaces, and then drying the slurry so as to solidify it. The formation of the desired crystalline phase of the coating occurs in situ on the coated passage surfaces during initial operation of the reformer. The coated packing material is operative to convert any free carbon remaining in the gas stream to carbon dioxide, or carbon monoxide, thereby further limiting carbon deposition in the assembly.

Inhibition of carbon deposition on fuel gas steam reformer walls

A heat exchanger uses the heat from processed fuel gas from a reformer for a fuel cell to superheat steam, to preheat raw fuel prior to entering the reformer and to heat a water-steam coolant mixture from the fuel cells. The processed fuel gas temperature is thus lowered to a level useful in the fuel cell reaction. The four temperature adjustments are accomplished in a single heat exchanger with only three heat transfer cores. The heat exchanger is preheated by circulating coolant and purge steam from the power section during startup of the latter.

Heat exchanger for fuel cell power plant reformer

High activity sulfur tolerant steam reforming catalysts are described comprising iridium, palladium or platinum supported on lanthanum stabilized alumina or magnesium promoted lanthanum stabilized alumina. The catalysts have improved activity over conventionally used catalysts in the presence of sulfur containing hydrocarbon fuels, particularly in a steam reforming environment. The catalysts have utility in autothermal, tubular, cyclic and adiabatic steam reforming processes.

Steam reforming catalyst

Steam reforming utilizing sulfur tolerant catalyst

High activity steam reforming iron oxide catalysts are described. Such catalysts can be unsupported utilizing at least 90% by weight iron oxide and various modifiers (Al.sub.2 O.sub.3, K.sub.2 O, CaO, SiO.sub.2) or unmodified and supported on such things as alumina, CaO impregnated alumina, and lanthanum stabilized alumina. When used in steam reformers such as autothermal and tubular steam reformers, these catalysts demonstrate much improved resistance to carbon plugging.

Steam reforming utilizing iron oxide catalyst

High activity, sulfur tolerant steam reforming catalysts are described comprising rhodium or nickel supported on lanthanum stabilized alumina or magnesium promoted lanthanum stabilized alumina. The catalysts have improved activity over conventionally used catalysts in the presence of sulfur containing hydrocarbon fuel (such as No. 2 fuel oil) in a steam reforming environment. The material has particular utility in autothermal, tubular, cyclic and adiabatic steam reforming processes.

Steam reforming utilizing high activity catalyst

High activity steam reforming catalysts are described particularly adapted for use in autothermal reforming processes. A rhodium catalyst on a calcium oxide impregnated alumina substrate allow the autothermal reforming process to take place with substantially no carbon plugging at oxygen to carbon ratios below what had been considered critical for avoiding carbon plugging of the catalyst in the past.

Autothermal reforming catalyst and process

Iron oxide catalyst for steam reforming

High activity steam reforming catalysts are described particularly adapted for use in autothermal reforming processes. A rhodium catalyst on a calcium oxide impregnated alumina substrate allows the autothermal reforming process to take place with substantially no carbon plugging at oxygen to carbon ratios below what had been considered critical for avoiding carbon plugging of the catalyst in the past.

Autothermal reforming catalyst

A catalytic combustor particularly adapted for use in wood and coal burning stoves is described comprising a high temperature stable support material containing a high activity, sulfur tolerant combustion catalyst. In addition to having a relatively long life, the catalytic combustors according to the present invention demonstrate useful performance even in the presence of sulfur containing fuels. Furthermore, the catalytic combustors of the present invention improve the efficiency of such stoves over and above that provided by conventional catalytic combustors.

Catalytic combustor

Catalyst for steam reforming

A catalytic combustor bed configuration particularly adapted for use in wood and coal burning stoves is described comprising a support screen having a layer of fully catalyst impregnated particulate material next to the screen, a layer of particulate material catalyzed on its outer surface next to the layer of fully impregnated material and a layer of uncatalyzed particulate material next to the outer surface catalyzed material. Optionally, a layer of uncatalyzed particulate material may be used between the screen and the fully impregnated particulate material. Such an arrangement, in addition to making maximum utilization of the catalyst material, also minimizes pressure drop across the catalytic combustor.

Combustion catalyst bed

In the hydrotreating and steam reforming of an oxygen and sulfur bearing hydrocarbon fuel the oxygen is first removed in an oxidizer containing a bed of platinum catalyst, the inlet temperature being well below 1000.degree. F. and preferably on the order of 300.degree. F. The sulfur in the fuel does not harm the oxidizer catalyst and may be removed downstream by known hydrodesulfurization techniques prior to reforming.

Process for alternately steam reforming sulfur containing hydrocarbons

Catalytic cracking of gaseous or distillate hydrocarbon fuels for the production of hydrogen (such as for use in a fuel cell) is provided in a push/pull operated dual chamber blow and run apparatus utilizing a catalytic bed employing ring catalyzed nickel supported on porous ceramic substrates, having a graduated catalyst content such that there is a low catalyst content in the portion of the bed near the inlet and a high catalyst content in the portion of the bed near the outlet.

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Ellington, CT, United States of America

Herbert J Setzer