Fast Startup, Fuel Flexible CPOX System for SOFC

In Phase I, Precision Combustion, Inc. (PCI) successfully designed, fabricated, and confirmed highly selective, near-equilibrium performance, of an 8 – 10 kW (thermal) catalytic partial oxidation (CPOX) reformer with multiple fuels, including propane, methane, and biogases with 4 different compositions. The reformer consisted of the catalytic reactor + housing + igniter + fuel/air injector. The CPOX catalytic reformer volume, weight, including all sub-components and sensors, were better than the solicitation metrics. It was demonstrated to produce sufficient reformate to generate at least 3 kW (electrical) when coupled with a Solid oxide Fuel Cell (SOFC). The reformer reached steady state within 30 seconds. Cyclic durability in excess of 100 cycles over 111 hours indicated stable operation. Hydrocarbon slip was avoided and risk of carbon formation mitigated. Capability to withstand MIL-SPEC-810 vibration requirements was also confirmed. A high-capacity mixed oxide sorbent for Biogas cleanup was identified by Penn State. All Phase I requirements and goals were met. A system design for a 1 – 3 kW lightweight generator was also developed. During Phase II, we will build on the Phase I results, and collaborate with UConn to optimize the CPOX catalyst to further improve the CPOX reformer performance and reduce CPOX reactor size. We will also advance the biogas cleanup sorbent by leveraging UConn’s biogas impurity cleanup research on both sulfur and siloxane, as well as PCI’s experience on gas cleanup and system design. The outcome will be a versatile sorbent/support combination, capable of removing both sulfur and siloxanes from biogas. We will demonstrate a breadboard generator prototype by coupling the CPOX with an SOFC stack, validate CPOX operation with biogas, propane, methane, and a liquid fuel, demonstrate long term durability over thousands of start/stop cycles, and confirm the ability to improve on all the solicitation metrics. A scalable standalone CPOX reformer will be a hardware deliverable at the end of Phase II. Success in Phase II will allow us to develop and mature a standalone generator in Phase III. Realization of the technical goals will lead to increasing the TRL and transitioning the generator to fielding via follow-on opportunities. PCI has a track record of transitioning SBIR developed technologies to advanced prototypes and fielding by collaborating with primes and commercial partners.