Coolant System for Fuel Processor

Abstract

A coolant subsystem for use in a fuel processor and a method for its operation are disclosed. In accordance with a first aspect, the coolant subsystem is separate from the feed to the processor reactor and is capable of circulating a coolant through the processor reactor. In accordance with a second aspect, the constituent elements of the fuel processor are housed in a cabinet, and the coolant subsystem is capable of cooling both the processor reactor and the interior of the cabinet. In various alternatives, the fuel processor can be employed to reform a fuel for a fuel cell power plant and/or may be used to provide thermal control for unrelated mechanical systems.

1 . A fuel processor, comprising: 
 a processor reactor;    a feed to the processor reactor; and    a coolant subsystem separate from the feed and capable of circulating a coolant through the processor reactor.    
   
   
       2 . The fuel processor of  claim 1 , wherein the processor reactor includes at least: 
 a first stage capable of receiving the feed and performing an autothermal reaction thereon;    a second stage capable of receiving the feed from the first stage and removing the sulfur therefrom;    a third stage capable of receiving the feed from the second stage and performing a first shift reaction thereon;    a fourth stage capable of receiving the feed from the third stage and performing a second shift reaction thereon; and    a fifth stage capable of receiving the feed from the fourth stage and preferentially oxidizing the received feed.    
   
   
       3 . The fuel processor of  claim 1 , wherein the feed to the processor reactor conveys a fuel, air, and water mixture.  
   
   
       4 . The fuel processor of  claim 1 , wherein the coolant subsystem includes: 
 a cooler capable of receiving coolant circulated from the processor reactor and exchanging heat therefrom;    a coolant storage capable of storing coolant received from the cooler; and    a pump capable of pumping the stored coolant to the process reactor.    
   
   
       5 . The fuel processor of  claim 4 , wherein the cooler comprises: 
 a heat exchanger; and    an air blower capable of cooling the heat exchanger.    
   
   
       6 . The fuel processor of  claim 5 , wherein the cooler further comprises: 
 a second heat exchanger; and    a second air blower capable of cooling the second heat exchanger.    
   
   
       7 . The fuel processor of  claim 4 , wherein the coolant comprises at least one of water, a glycol, an oil, and an alcohol.  
   
   
       8 . The fuel processor of  claim 4 , wherein the coolant storage comprises a tank.  
   
   
       9 . The fuel processor of  claim 1 , further comprising: 
 an oxidizer capable of heating fuel, water, and air and feeding the mixture to the process reactor via the feed;    a fuel supply subsystem of providing fuel to the oxidizer;    a water subsystem capable of providing water to the oxidizer;    an air subsystem capable of providing air to the oxidizer.    
   
   
       10 . The fuel processor of  claim 1 , further comprising a connection to the at least one external user.  
   
   
       11 . The fuel processor of  claim 10 , wherein the connection comprises an outlet and an inlet through which the coolant may be circulated to an external user.  
   
   
       12 . The fuel processor of  claim 10 , further comprising an oxidizer capable preheating fuel, water, and air to generate a process feed stream introduced to the processor reactor through the feed.  
   
   
       13 . The fuel processor of  claim 12 , wherein the oxidizer comprises an anode tailgas oxidizer.  
   
   
       14 . The fuel processor of  claim 1 , wherein the coolant subsystem further comprises a plurality of temperature control units, each temperature control unit including: 
 a temperature sensor sensing the temperature of the coolant in a portion of the processor reactor through which the coolant is circulating; and    an actuator operated responsive to the sensed temperature in the portion to throttle to flow of coolant through the portion.    
   
   
       15 . A power plant, comprising: 
 a fuel processor, including: 
 a processor reactor generating a reformate;  
 a feed to the processor reactor; and  
 a coolant subsystem separate from the feed and capable of circulating a coolant through the processor reactor; and  
 a fuel cell powered by the reformate generated by the processor reactor of the fuel processor.  
   
   
   
       16 . The power plant of  claim 15 , wherein the processor reactor includes at least: 
 a first stage capable of receiving the feed and performing an autothermal reaction thereon;    a second stage capable of receiving the feed from the first stage and removing the sulfur therefrom;    a third stage capable of receiving the feed from the second stage and performing a first shift reaction thereon;    a fourth stage capable of receiving the feed from the third stage and performing a second shift reaction thereon; and    a fifth stage capable of receiving the feed from the fourth stage and preferentially oxidizing the received feed.    
   
   
       17 . The power plant of  claim 15 , wherein the feed to the processor reactor conveys a fuel, air, and water mixture.  
   
   
       18 . The power plant of  claim 15 , wherein the coolant subsystem includes: 
 a cooler capable of receiving coolant circulated from the processor reactor and exchanging heat therefrom;    a coolant storage capable of storing coolant received from the cooler; and    a pump capable of pumping the stored coolant to the process reactor.    
   
   
       19 . The power plant of  claim 15 , wherein the cooler comprises: 
 a heat exchanger; and    an air blower capable of cooling the heat exchanger by convection.    
   
   
       20 . The power plant of  claim 19 , wherein the cooler further comprises: 
 a second heat exchanger; and    a second air blower capable of cooling the second heat exchanger by convection.    
   
   
       21 . The power plant of  claim 18 , wherein the coolant comprises at least one of water, a glycol, an oil, and an alcohol.  
   
   
       22 . The power plant of  claim 18 , wherein the coolant storage comprises a tank.  
   
   
       23 . The power plant of  claim 15 , further comprising: 
 an oxidizer capable of preheating fuel, water, and air and feeding the mixture to the process reactor via the feed;    a fuel supply subsystem of providing fuel to the oxidizer;    a water subsystem capable of providing water to the oxidizer;    an air subsystem capable of providing air to the oxidizer.    
   
   
       24 . The power plant of  claim 15 , further comprising a connection to the at least one external user.  
   
   
       25 . The power plant of  claim 24 , wherein the connection comprises an outlet and an inlet through which the coolant may be circulated.  
   
   
       26 . The power plant of  claim 15 , wherein the coolant subsystem further comprises a plurality of temperature control units, each temperature control unit including: 
 a temperature sensor sensing the temperature of the coolant in a portion of the fuel processor through which the coolant is circulating; and    an actuator operated responsive to the sensed temperature in the portion to throttle to flow of coolant through the portion.    
   
   
       27 . The power plant of  claim 15 , wherein the fuel cell comprises a polymer electrolyte fuel cell.  
   
   
       28 . A method for use in processing a fuel for use in fuel processor, comprising: 
 feeding a fuel, water, and air mixture to a processor reactor;    reforming the mixture in the processor reactor; and    cooling the processor reactor with a coolant separate from the feed mixture to control the temperature of the reforming.    
   
   
       29 . The method of  claim 28 , wherein reforming the mixture includes: 
 performing an autothermal reaction;    cleaning sulfur from the feed;    performing at least one shift reaction from the cleaned feed; and    performing a preferential oxidation on the shifted feed.    
   
   
       30 . The method of  claim 28 , wherein cooling the process reactor with a coolant include cooling the process reactor with at least one of water, a glycol, an oil, and an alcohol.  
   
   
       31 . The method of  claim 28 , wherein cooling the processor reactor with the coolant separate from the feed mixture includes circulating the coolant through the processor reactor.  
   
   
       32 . The method of  claim 31 , wherein circulating the coolant through the processor reactor includes: 
 exchanging heat from the coolant circulated from the processor reactor;    storing cooled coolant received; and    pumping the stored coolant to the process reactor.    
   
   
       33 . The method of  claim 31 , wherein exchanging heat from the coolant includes cooling the coolant by convection.  
   
   
       34 . The method of  claim 28 , wherein cooling the processor reactor with the coolant includes: 
 sensing the temperature of a portion of the processor reactor through which the coolant circulates; and    throttling a supply of the coolant through the portion of the processor responsive to the sensed temperature.    
   
   
       35 . The method of  claim 28 , further comprising circulating the coolant to at least one external user.  
   
   
       36 . A power plant, comprising: 
 a cabinet;    a fuel processor contained in the cabinet, the fuel processor including: 
 a processor reactor;  
 a feed to the processor reactor; and  
   a coolant subsystem capable of cooling the processor reactor and the interior of the cabinet;    a fuel cell contained in the cabinet and powered by the reformate generated by the processor reactor of the fuel processor.    
   
   
       37 . The fuel processor of  claim 36 , wherein the processor reactor includes at least: 
 a first stage capable of receiving the feed and performing an autothermal reaction thereon;    a second stage capable of receiving the feed from the first stage and removing the sulfur therefrom;    a third stage capable of receiving the feed from the second stage and performing a first shift reaction thereon;    a fourth stage capable of receiving the feed from the third stage and performing a second shift reaction thereon; and    a fifth stage capable of receiving the feed from the fourth stage and preferentially oxidizing the received feed.    
   
   
       38 . The fuel processor of  claim 36 , wherein the feed to the processor reactor conveys a fuel, air, and water mixture.  
   
   
       39 . The power plant of  claim 36 , wherein the coolant subsystem is capable of receiving coolant circulated from the processor reactor and exchanging heat therefrom to cool the processor reactor and capable of circulating heat from the interior of the cabinet to the exterior of the cabinet to cool the interior of the cabinet.  
   
   
       40 . The power plant of  claim 39 , wherein the coolant subsystem comprises: 
 a heat exchanger; and    an air blower capable of cooling the heat exchanger and the cabinet interior by convection.    
   
   
       41 . The power plant of  claim 40 , wherein the cooler further comprises: 
 a second heat exchanger; and    a second air blower capable of cooling the heat exchanger and the cabinet interior by convection.    
   
   
       42 . The power plant of  claim 39 , wherein the coolant comprises at least one of water, a glycol, an oil, and an alcohol.  
   
   
       43 . The power plant of  claim 36 , wherein the coolant subsystem includes a cooler capable of receiving coolant circulated from the processor reactor and exchanging heat therefrom and capable of circulating heat from the interior of the cabinet to the exterior of the cabinet.  
   
   
       44 . The power plant of  claim 43 , wherein the coolant subsystem further includes: 
 a coolant storage capable of storing coolant received from the cooler; and    a pump capable of pumping the stored coolant to the process reactor.    
   
   
       45 . The power plant of  claim 43 , wherein the cooler comprises: 
 a heat exchanger; and    an air blower capable of cooling the heat exchanger and the cabinet interior by convection.    
   
   
       46 . The power plant of  claim 43 , wherein the cooler further comprises: 
 a second heat exchanger; and    a second air blower capable of cooling the heat exchanger and the cabinet interior by convection.    
   
   
       47 . The power plant of  claim 44 , wherein the coolant storage comprises a tank.  
   
   
       48 . The power plant of  claim 36 , wherein the coolant subsystem includes: 
 a cooler capable of receiving coolant circulated from the processor reactor and exchanging heat therefrom;    a coolant storage capable of storing coolant received from the cooler; and    a pump capable of pumping the stored coolant to the process reactor.    
   
   
       49 . The power plant of  claim 36 , further comprising: 
 an oxidizer capable of preheating fuel, water, and air and feeding the mixture to the process reactor via the feed;    a fuel supply subsystem of providing fuel to the oxidizer;    a water subsystem capable of providing water to the oxidizer;    an air subsystem capable of providing air to the oxidizer.    
   
   
       50 . The power plant of  claim 36 , further comprising a connection to the at least one external user.  
   
   
       51 . The power plant of  claim 50 , wherein the connection comprises an outlet and an inlet through which the coolant may be circulated.  
   
   
       52 . The fuel processor of  claim 36 , wherein the coolant subsystem further comprises a plurality of temperature control units, each temperature control unit including: 
 a temperature sensor sensing the temperature of the coolant in a portion of the fuel processor through which the coolant is circulating; and    an actuator operated responsive to the sensed temperature in the portion to throttle to flow of coolant through the portion.    
   
   
       53 . The power plant of  claim 36 , wherein the fuel cell comprises a polymer electrolyte fuel cell.  
   
   
       54 . A method for cooling a fuel processor, comprising: 
 circulating a coolant through a processor reactor of the fuel processor; and    cooling the circulated fluid through convection, the convection also circulating heated air from the interior of a cabinet for the fuel processor to the exterior.    
   
   
       55 . The method of  claim 54 , wherein circulating the coolant through the processor reactor includes circulating the coolant through several different portions of the processor reactor.  
   
   
       56 . The method of  claim 54 , wherein circulating the coolant through the processor reactor includes circulating at least one of water, a glycol, an oil, and an alcohol.  
   
   
       57 . The method of  claim 54 , wherein circulating the coolant through the processor reactor includes circulating the coolant through the processor reactor separately from a feed to the processor reactor.  
   
   
       58 . The method of  claim 54 , wherein cooling the circulating fluid through convection includes: 
 circulating the coolant through a heat exchanger; and    blowing air across the heat exchanger.    
   
   
       59 . The method of  claim 58 , wherein cooling the circulating fluid through convection includes: 
 circulating the coolant through a second heat exchanger; and    blowing air across the second heat exchanger.    
   
   
       60 . The method of  claim 58 , wherein blowing air across the heat exchanger circulates the heated air from the interior of the cabinet to the exterior.  
   
   
       61 . A method for cooling a power plant, comprising. 
 circulating a coolant through a processor reactor of a fuel processor; and    cooling the circulated fluid through convection, the convection also circulating heated air from the interior of a cabinet for the power plant to the exterior.    
   
   
       62 . The method of  claim 61 , wherein circulating the coolant through the processor reactor includes circulating the coolant through several different portions of the processor reactor.  
   
   
       63 . The method of  claim 61 , wherein circulating the coolant through the processor reactor includes circulating at least one of water, a glycol, an oil, and an alcohol.  
   
   
       64 . The method of  claim 61 , wherein circulating the coolant through the processor reactor includes circulating the coolant through the processor reactor separately from a feed to the processor reactor.  
   
   
       65 . The method of  claim 61 , wherein cooling the circulating fluid through convection includes: 
 circulating the coolant through a heat exchanger; and    blowing air across the heat exchanger.    
   
   
       66 . The method of  claim 65 , wherein cooling the circulating fluid through convection includes: 
 circulating the coolant through a second heat exchanger; and    blowing air across the second heat exchanger.    
   
   
       67 . A fuel processor, comprising: 
 a processor reactor;    a feed to the processor reactor;    a coolant subsystem capable of circulating a coolant through the processor reactor; and    a connection to at least one external user of the fuel processor.    
   
   
       68 . The fuel processor of  claim 67 , wherein the processor reactor includes at least: 
 a first stage capable of receiving the feed and performing an autothermal reaction thereon;    a second stage capable of receiving the feed from the first stage and removing the sulfur therefrom;    a third stage capable of receiving the feed from the second stage and performing a first shift reaction thereon;    a fourth stage capable of receiving the feed from the third stage and performing a second shift reaction thereon; and    a fifth stage capable of receiving the feed from the fourth stage and preferentially oxidizing the received feed.    
   
   
       69 . The fuel processor of  claim 67 , wherein the feed to the processor reactor conveys a fuel, air, and water mixture.  
   
   
       70 . The fuel processor of  claim 67 , wherein the coolant subsystem includes: 
 a cooler capable of receiving coolant circulated from the processor reactor and exchanging heat therefrom;    a coolant storage capable of storing coolant received from the cooler; and    a pump capable of pumping the stored coolant to the process reactor.    
   
   
       71 . The fuel processor of  claim 70 , wherein the cooler comprises: 
 a heat exchanger; and    an air blower capable of cooling the heat exchanger.    
   
   
       72 . The fuel processor of  claim 70 , wherein the coolant comprises at least one of water, a glycol, an oil, and an alcohol.  
   
   
       73 . The fuel processor of  claim 70 , wherein the coolant storage comprises a tank.  
   
   
       74 . The fuel processor of  claim 67 , further comprising. 
 an oxidizer capable of heating fuel, water, and air and feeding the mixture to the process reactor via the feed;    a fuel supply subsystem of providing fuel to the oxidizer;    a water subsystem capable of providing water to the oxidizer;    an air subsystem capable of providing air to the oxidizer.    
   
   
       75 . The fuel processor of  claim 67 , wherein the external user comprises a mechanical system not otherwise associated with the fuel processor.  
   
   
       76 . The fuel processor of  claim 75 , wherein the mechanical system an air conditioning/heating mechanical system.  
   
   
       77 . The fuel processor of  claim 67 , wherein the connection comprises an outlet and an inlet through which the coolant may be circulated to an external user.  
   
   
       78 . The fuel processor of  claim 67 , further comprising an oxidizer capable preheating fuel, water, and air to generate a process feed stream introduced to the processor reactor through the feed.  
   
   
       79 . The fuel processor of  claim 67 , wherein the coolant subsystem further comprises a plurality of temperature control units, each temperature control unit including: 
 a temperature sensor sensing the temperature of the coolant in a portion of the processor reactor through which the coolant is circulating; and    an actuator operated responsive to the sensed temperature in the portion to throttle to flow of coolant through the portion.    
   
   
       80 . A power plant, comprising: 
 a fuel processor, including: 
 a processor reactor generating a reformate;  
 a feed to the processor reactor; and  
 a coolant subsystem capable of circulating a coolant through the processor reactor; and  
 a connection to at least one external user of the fuel processor; and  
 a fuel cell powered by the reformate generated by the processor reactor of the fuel processor.  
   
   
   
       81 . The power plant of  claim 80 , wherein the processor reactor includes at least: 
 a first stage capable of receiving the feed and performing an autothermal reaction thereon;    a second stage capable of receiving the feed from the first stage and removing the sulfur therefrom;    a third stage capable of receiving the feed from the second stage and performing a first shift reaction thereon;    a fourth stage capable of receiving the feed from the third stage and performing a second shift reaction thereon; and    a fifth stage capable of receiving the feed from the fourth stage and preferentially oxidizing the received feed.    
   
   
       82 . The power plant of  claim 80 , wherein the feed to the processor reactor conveys a fuel, air, and water mixture.  
   
   
       83 . The power plant of  claim 80 , wherein the coolant subsystem includes: 
 a cooler capable of receiving coolant circulated from the processor reactor and exchanging heat therefrom;    a coolant storage capable of storing coolant received from the cooler; and    a pump capable of pumping the stored coolant to the process reactor.    
   
   
       84 . The power plant of  claim 80 , wherein the cooler comprises: 
 a heat exchanger; and    an air blower capable of cooling the heat exchanger by convection.    
   
   
       85 . The power plant of  claim 84 , wherein the cooler further comprises: 
 a second heat exchanger; and    a second air blower capable of cooling the second heat exchanger by convection.    
   
   
       86 . The power plant of  claim 83 , wherein the coolant comprises at least one of water, a glycol, an oil, and an alcohol.  
   
   
       87 . The power plant of  claim 83 , wherein the coolant storage comprises a tank.  
   
   
       88 . The power plant of  claim 80 , further comprising: 
 an oxidizer capable of preheating fuel, water, and air and feeding the mixture to the process reactor via the feed;    a fuel supply subsystem of providing fuel to the oxidizer;    a water subsystem capable of providing water to the oxidizer;    an air subsystem capable of providing air to the oxidizer.    
   
   
       89 . The power plant of  claim 80 , wherein the external user comprises a mechanical system not otherwise associated with the fuel processor.  
   
   
       90 . The power plant of  claim 89 , wherein the mechanical system an air conditioning/heating mechanical system.  
   
   
       91 . The power plant of  claim 80 , wherein the connection comprises an outlet and an inlet through which the coolant may be circulated.  
   
   
       92 . The power plant of  claim 80 , wherein the coolant subsystem further comprises a plurality of temperature control units, each temperature control unit including: 
 a temperature sensor sensing the temperature of the coolant in a portion of the fuel processor through which the coolant is circulating; and    an actuator operated responsive to the sensed temperature in the portion to throttle to flow of coolant through the portion.    
   
   
       93 . The power plant of  claim 80 , wherein the fuel cell comprises a polymer electrolyte fuel cell.