Novel Fuel Reformer for Undersea Applications

The major drawback to the use of fuel cells as electric generators in unmanned undersea vehicles (UUVs) is their inability to directly use battlefield fuels. In order to efficiently use heavy hydrocarbon fuels (e.g., JP-8, diesel, dodecane) in an air independent environment, the fuel must first be reformed to a hydrogen-rich synthesis gas stream in a highly energy intensive process which is inherently inefficient. TDA Research, Inc. (TDA) proposes to develop a novel fuel processor that allows the heat generated in the Solid Oxide Fuel Cell (SOFC) stacks to be utilized to drive the endothermic steam reforming process. Due to the better heat management by coupling the reformer with the SOFC stacks, TDA’s fuel processor operates very efficiently and minimizes the amount of fuel and oxidant storage needed to support the operation of the fuel cell. In Phase I, we showed that our fuel processing approach is a viable solution for a high energy density power generator that could meet the future requirements of the UUVs (the proposed system could achieve a specific energy of 372 W-hr/kg and an energy density of 428 W-hr/L, meeting NUWC’s requirements of 350 W-hr/kg and 350 W-hr/L. We demonstrated the performance capabilities of a commercial reforming catalyst under representative conditions and carried out the system design, showing favorable weight and volume characteristics. In Phase II, the key objective is to demonstrate the effectiveness of all fuel processing system components at full-scale first in a stand-alone manner and then in combination with a fuel cell. In achieving this goal, we will develop a follow a breadboard fuel processor to demonstrate the key aspects of the novel fuel processor. The concept demonstrations will be carried out on a breadboard system that will not be designed for compactness and lightweight; nevertheless it will serve as an excellent platform to support future design and development. Finally, in our collaboration with a leading SOFC manufacturer, we will demonstrate the full potential of the integrated power generation system.