Catalytic partial oxidation of hydrocarbon fuels to hydrogen and carbon monoxide

Abstract

A method of processing sulfur-containing heavy hydrocarbon fuels in the substantial absence of steam through catalytic partial oxidation is described. The process comprises the steps of vaporizing a heavy hydrocarbon fuel and bringing the vaporized fuel and oxidizer mixture in contact with a noble metal catalyst supported on an open channel structure. The hydrocarbon fuel is considered to be a liquid hydrocarbon having at least six carbon atoms and a sulfur content of at least 50 ppm. The feed, containing only the vaporized fuel and oxygen in the oxidizer mixture, is subsequently routed through a reactor containing a noble metal catalyst (typically Rh/Alumina) at contact times of not more than about 500 milliseconds and a LHSV of not less than about 0.5 h,. The feed is partially oxidized by a catalytic reaction occurring at a temperature of no less than about 1050° C., with the catalytic partial oxidation process producing essentially complete conversion of hydrocarbons present in the feed to hydrogen and carbon monoxide. The sulfur compounds in the feed are predominantly converted into hydrogen sulfide. The product gas consisting mainly of carbon monoxide and hydrogen can then be recovered or, alternatively, directed to a solid oxide fuel cell system.