Reformer and Method of Startup

Abstract

A linear reformer for liberating hydrogen from a hydrogen containing feedstock, operable on both gaseous and liquid fuels, has a linear burner distributor with at least two fuel distribution apertures for distribution of fuel, a supply of air, where the fuel and air mix in a linear mixing cavity to form a catalytically combustible mixture, a catalytic burner element, an electric heater in heat transferring relation to at least one of the burner distributor and the catalytic burner element, a catalyst bed, a boiler for boiling and heating the feedstock, and an exhaust heat exchanger effective for pre-heating the supply of air to the burner. The burner distributor, catalyst bed, feedstock boiler, and exhaust heat exchanger are all linear elements with a common parallel axis, such that heat exchange gases from the burner travel transversely to the common parallel axis, and where the burner distributor receives heat from the electric heater such that incoming fuel may be at least partially vaporized, and the electric heater heats the catalytic burner element to sufficient temperature such that the vaporized fuel and air mixture initiates catalytic combustion.

1 . A burner for a reformer for liberating hydrogen from a hydrogen containing feedstock, operable on both gaseous and liquid fuels, comprising:
 a substantially linear burner distributor with at least two fuel distribution apertures for distribution of fuel;   a supply of air in a substantially linear mixing cavity which is substantially parallel with the axis of the burner distributor, where the at least two fuel distribution apertures supply burner fuel, and the fuel and air mix to form a catalytically combustible mixture;   a catalytic burner element; and   an at least one electric heater in heat transferring relation to at least one of said burner distributor and the catalytic burner element;   
     where the burner distributor receives heat from the at least one electric heater such that incoming liquid fuel may be at least partially vaporized, and the at least one electric heater heats the catalytic burner element to sufficient temperature such that the vaporized fuel and air mixture initiates catalytic combustion, and the flow of burner air is substantially transverse to the linear axis of the burner distributor. 
   
   
       2 . The burner as claimed in  claim 1 , where the burner distributor is a porous tubular element. 
   
   
       3 . The burner as claimed in  claim 1 , where the electric heater is contained within a burner distributor cavity, such that liquid fuel arriving at the burner distributor comes into direct contact with said electric heater prior to exiting the distribution apertures. 
   
   
       4 . The burner as claimed in  claim 3 , where the electric heater and burner distributor are tubular and concentric with each other. 
   
   
       5 . The burner as claimed in  claim 4 , where the heater further supplies sufficient heat to achieve a fuel and air light-off temperature within the catalytic burner element. 
   
   
       6 . The burner as claimed in  claim 1  including an electric pre-heater to add heat to the fuel arriving at the burner distributor, prior to the introduction of the fuel into the burner distributor. 
   
   
       7 . A linear reformer for liberating hydrogen from a hydrogen containing feedstock, operable on both gaseous and liquid fuels, comprising:
 a burner distributor with at least two fuel distribution apertures for distribution of fuel;   a supply of air, where the at least two fuel distribution apertures supply burner fuel, and the fuel and air mix to form a catalytically combustible mixture;   a catalytic burner element;   an at least one electric heater in heat transferring relation to at least one of said burner distributor and the catalytic burner element;   a catalyst bed;   a boiler for boiling and heating a feedstock;   an exhaust heat exchanger effective for pre-heating the supply of air to the burner;   
     where the burner distributor, catalyst bed, feedstock boiler, and exhaust heat exchanger are substantially linear elements with a substantially common parallel axis, such that heat exchange gases from the burner travel substantially transversely to the common parallel axis, and where the burner distributor receives heat from the at least one electric heater such that incoming liquid fuel may be at least partially vaporized, and the at least one electric heater heats the catalytic burner element to sufficient temperature such that the vaporized fuel and air mixture initiates catalytic combustion. 
   
   
       8 . The reformer as claimed in  claim 7 , where the exhaust heat exchanger comprises:
 at least three heat exchange plates with openings allowing for the passage of two counterflow heat exchange gases; and   insulating gaskets between the plates, where the gaskets form a gas barrier between the counterflow heat exchange gases, and where the gaskets and plates form a stacked assembly.   
   
   
       9 . The reformer as claimed in  claim 7 , where the heat exchanger plates are stacked such that the heat exchange gases change direction between successive openings in heat exchange plates. 
   
   
       10 . A linear reformer for liberating hydrogen from a hydrogen containing feedstock, operable on both gaseous and liquid fuels, comprising:
 a burner distributor with at least two fuel distribution apertures for distribution of fuel;   a supply of air, where the at least two fuel distribution apertures supply burner fuel, and the fuel and air mix to form a catalytically combustible mixture;   a catalytic burner element;   an at least one electric heater in heat transferring relation to at least one of said burner distributor and the catalytic burner element;   a catalyst bed;   a boiler for boiling and heating a feedstock;   an at least one exhaust heat exchanger assembly effective for pre-heating the supply of air to the burner;
 at least three heat exchange plates with openings allowing for the passage of two counterflow heat exchange gases; 
 insulating gaskets between the plates, where the gaskets form a gas barrier between the counterflow heat exchange gases, and where the gaskets and plates form a stacked assembly; and 
   
     where the burner distributor, catalyst bed, feedstock boiler, and exhaust heat exchanger are substantially linear elements with a substantially common parallel axis, such that heat exchange gases from the burner travel substantially transversely to the common parallel axis, and where the burner distributor receives heat from the at least one electric heater such that incoming liquid fuel may be at least partially vaporized, and the at least one electric heater heats the catalytic burner element to sufficient temperature such that the vaporized fuel and air mixture initiates catalytic combustion. 
   
   
       11 . The reformer as claimed in  claim 10 , where the exhaust heat exchanger comprises at least two heat exchanger assemblies, and at least one plenum in between two of the exhaust heat exchanger assemblies for each respective heat exchange gas, and where the reformed gases from the catalyst bed travel to said plenum for at least one further processing step including at least one of heat exchange and a catalytic process. 
   
   
       12 . The reformer as claimed in  claim 11  where the further processing step comprises reducing the temperature of the reformed gases and introducing the gases to low temperature shift bed, and where the temperature reduction is accomplished by shedding heat to either the air incoming into the burner or the exhaust flue gas with a heat exchanger, and the heat exchanger and catalyst bed are contained within one or both of the plenums defined between the exhaust heat exchanger assemblies. 
   
   
       13 . The reformer as claimed in  claim 10 , including a hydrogen purifier to separate the hydrogen from the reformed gases produced in the catalyst bed. 
   
   
       14 . The reformer as claimed in  claim 13 , where the purifier utilizes a metallic membrane to separate the hydrogen. 
   
   
       15 . A method for initiating operation of a reformer for the production of hydrogen from a hydrogen-containing feedstock, comprising in sequence:
 preheating a multi-apertured linear burner distributor with an electric heater sufficient to vaporize liquid fuel;   preheating a catalytic burner with an electric heater sufficient to achieve light-off temperature for a given fuel and air mix;   pumping liquid fuel into the preheated burner distributor;   adding oxidant air to the vaporized fuel;   operating the fuel pump and air supply sufficient to achieve operation of the catalytic combustion burner;   turning off said electric heaters when no longer needed for efficient burner operation; and   operating the burner using liquid fuel until sufficient heat has built up in the reformer to initiate steam reforming, and subsequently utilizing reformed gases as a fuel supply for the burner.