Reformer for Conversion of Diesel Fuel into CO and Hydrogen

A major impediment to the commercialization of solid oxide fuel cell systems for the very large automotive market is the lack of efficient, low-cost, compact reformers to convert diesel fuel into synthesis gas. The major issues involve carbon deposition in the cooler zones of the reformer and catalyst intolerance to sulfur. This project will develop a reformer that integrates a modified oxygen transport membrane material with sulfur-tolerant reforming catalysts. The system, which uses commercial grade diesel as a feedstock, prevents carbon build-up by transporting the oxygen through self-cleaning reformer walls. The system will be compact and inexpensive, and will operate stably. In Phase I, catalysts were designed for the partial oxidation of diesel fuel into synthesis gas, using oxides with high conductivity of both electrons and oxygen anions. Some 40 catalyst formulations were evaluated. The preferred self-cleaning catalysts showed stable reforming activity without carbon deposition for pump-grade diesel fuel. In Phase II, the catalysts will be incorporated into self-cleaning reformer walls, and the system will be optimized and tested. A design for a commercial prototype diesel fuel reformer will be completed and a techno-economic analysis, leading to commercialization in Phase III, will be performed. Commercial Applications and other Benefits as described by the awardee: The sulfur-tolerant fuel reformer, which should cost less than $90 per kW and have an overall efficiency greater than 80%, would enable the wide-spread adoption of diesel-based solid oxide fuel cell systems. Such reformers also would allow conversion of very-high-sulfur military fuel and bottom-of-the-barrel petroleum reserves into synthesis gas. The synthesis gas from the latter could be used to run turbines or to produce alternative fuels, including low-sulfur diesel, methanol, and synthetic natural gas