Process and apparatus for reforming a high sulfur-containing liquid fuel

Abstract

A reforming process and apparatus exhibiting improved catalyst longevity towards reforming a high sulfur-containing liquid fuel. The process involves contacting in a first reforming zone a first oxidant and a liquid fuel containing high molecular weight organosulfur compounds with a partial oxidation catalyst under CPOX reaction conditions to form a first reformate stream containing a mixture of unconverted and partially-converted hydrocarbons and one or more low molecular weight sulfur compounds; and then contacting in a second reforming zone the first reformate stream with steam and optionally a second oxidant in the presence of an autothermal reforming catalyst under ATR reaction conditions to form a second reformate stream containing carbon monoxide and hydrogen and one or more low molecular weight sulfur compounds. The low molecular weight sulfur compounds can be readily removed from the first and/or second reformate streams by gas phase adsorption methods.

1 .- 18 . (canceled) 
     
     
         19 . A fuel processor system for reforming a high sulfur-containing liquid fuel comprising:
 (a) a first reforming zone; a first inlet for feeding a high sulfur-containing liquid fuel into said first reforming zone; a second inlet for feeding a first oxidant into said first reforming zone; a partial oxidation catalyst located within said first reforming zone in fluid communication with said first and second inlets; and a first outlet in fluid communication with said partial oxidation catalyst for exiting a first reformate stream from said first reforming zone; and   (b) a second reforming zone positioned downstream of said first reforming zone; a third inlet in fluid communication with the first outlet from said first reforming zone, the third outlet for feeding the first reformate stream into said second reforming zone; a fourth inlet for feeding a second oxidant into said second reforming zone; a fifth inlet for feeding steam into said second reforming zone; an autothermal reforming catalyst positioned in said second reforming zone in fluid communication with said third, fourth, and fifth inlets; and a second outlet positioned in fluid communication with said autothermal reforming catalyst for exiting a second reformate stream from said second reforming zone.   
     
     
         20 . The system of  claim 19  wherein the first reforming zone and the second reforming zone are sequentially connected within one housing; or alternatively, wherein the first reforming zone and the second reforming zone are located in separate sequentially-connected housings. 
     
     
         21 . The system of  claim 19  further comprising a sulfur adsorbent bed downstream of said second reforming zone; the sulfur adsorbent bed having an inlet in fluid communication with said outlet of said second reforming zone and having an outlet for exiting a desulfurized second reformate stream. 
     
     
         22 . The system of  claim 21  additionally comprising a heat exchanger positioned in-between the second reforming zone and the sulfur adsorbent bed, wherein the heat exchanger is configured with an inlet for feeding the second reformate stream into the heat exchanger, the inlet being disposed in fluid communication with the outlet of the second reforming zone, and wherein the heat exchanger is further configured with an outlet for exiting the second reformate stream from the heat exchanger to the inlet to the sulfur adsorbent bed. 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . The system of  claim 22  wherein the heat exchanger comprises a second outlet configured in fluid communication with the second reforming zone. 
     
     
         26 . The system of  claim 19  wherein the partial oxidation catalyst comprises an ultra-short-channel-length metal substrate having an ultra-short-channel-length ranging from 25 microns to 500 microns. 
     
     
         27 . The system of  claim 26  wherein the metal substrate has one or more noble metals deposited thereon. 
     
     
         28 . The system of  claim 19  wherein the autothermal reforming catalyst comprises an ultra-short-channel-length metal substrate having an ultra-short-channel-length ranging from 25 microns to 500 microns. 
     
     
         29 . The system of  claim 28  wherein the metal substrate has one or more noble metals deposited thereon. 
     
     
         30 . The system of  claim 19  wherein the partial oxidation catalyst and the autothermal reforming catalyst each independently comprise an ultra-short-channel-length metal substrate having one or more noble metals deposited thereon, the ultra-short-channel-length ranging from 25 microns to 500 microns.