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Gas Processing Unit Development Review Meeting, May 11, 2005

This review meeting discusses progress in developing a Gas Processing Unit focusing on butane reforming, coating, micromachining, and heat exchange integration. Milestones, project management, and results after 12 months are outlined.

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Gas Processing Unit Development Review Meeting, May 11, 2005

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  1. NTB INTERSTAATLICHE HOCHSCHULE FÜR TECHNIK BUCHS KTI Review Meeting, May 11, 2005 Workpackage 2: Gas Processing Unit M. Stutz, N. Hotz, Dr. N. Bieri, and Prof. D. Poulikakos

  2. Contributions to WP 2 NMW NMW Butane Reforming Coating Coating NTB Micromachining NTB Heat exchange Feed / Exhaust Coating Coating Micromachining Post Combustion Integration and Testing Inlet conditions Compatibility with FC

  3. WP 2: Year 1 Milestones • performance 200 mW/cm2 @ 550°C • external electrical connections Fuel Cell • butane conversion rate > 90% • post-combustor with gas oxidation > 98% Gas Processing • thermal insulation concept with • Tinside 550°C, Toutside 50°C, <10 cm3 • structures for validation critical points • thermal system demonstrator with • simulated 2 W heat source Thermal System Project Management • battery expert • industrial partner

  4. Main Achievement after 12 Months • Optimized butane reforming performance at 600˚C! Results @ Month 6 Hydrogen Yield: Results @ month 12

  5. Overview • Our Main Task in this Project • WP 2.1: Reformer • WP 2.2: Post-Combustor • WP 2.3: Integration and Testing • Validation of Milestones • Next Steps

  6. Our Main Task in this Project • FC System: • Reformer: • Post Combustor (PC):

  7. Overview • Our Main Task in this Project • WP 2.1: Reformer • WP 2.2: Post-Combustor • WP 2.3: Integration and Testing • Validation of Milestones • Next Steps

  8. WP 2.1: Reformer Main Tasks: • Understanding the butane reforming at low temperature (600˚C)? • Experiments with packed bed reformer • influence of plugs is significant • activation/deactivation of catalyst • Reforming with the disk reactor: • Coating of the disk reactor • Influence of sealing • Activation/deactivation of catalyst • New challenge • Modified product specification (from 1 W to 2.5 W power output) • Build-up of modified test rig

  9. Month 12: Milestones (MS) • MS @ month 12: reformer demonstrator with significant butane conversion rate @ 600°C and stable for feeds of 0.02 to 0.5 g/h butane incl. gas chromatography (fabrication: NTB, testing: LTNT) • Optimized experiments: packed bed reformer • Modified design in progress (disk reactor) 

  10. Experimental Results • Comparison: Packed bed reactor • Empty tube • Reformer with plugs 'O' (Al2O3/SiO2, old) • Reformer with plugs 'N' (SiO2, new) • Thermodynamic equilibrium

  11. Reactor Performance • for T > 450 °C: • high η for 'plugs N' • for T < 450 °C: • high η for 'plugs O' • η of empty tube is low • effect of catalyst • Butane conversion POX • at T = 600 °C: • η = 69.2 % for 'plugs O' • η = 93.0 % for 'plugs N' TOX Total Oxidation (TOX): C4H10 + 6.5 O2→5 H2O + 4 CO2 Partial Oxidation (POX): C4H10 + 2 O2→5 H2 + 4 CO

  12. Reactor Performance • for T > 450 °C: • high ψ for 'plugs N' • for T < 450 °C: • high ψ for 'plugs O' • ψ is higher than equilibrium • Hydrogen Yield TOX • at T = 600 °C: • ψ = 45.5 % for 'plugs O' • ψ = 86.6 % for 'plugs N' POX TOX: C4H10 + 6.5 O2→5 H2O + 4 CO2 POX: C4H10 + 2 O2→5 H2 + 4 CO

  13. Outlet composition • Reformer with plugs 'N' (SiO2, new) • Outlet composition: • at T = 600 °C: • XH2O = 4.6% • XH2 = 23.0% • XCO = 13.2% • Enhanced FC performance if XH2O≈ 5% TOX POX → Inlet conditions of FC to NMW / EPFL

  14. Disk reactor • Experimental results of Disk reactor • Coating: Rh (sputtered by NTB) • T = 600°C, ddisk = 8 mm, GSV = 25 s-1 Butane Conversion: PBR Reason: • Sealing? • Coating? DR Hydrogen Yield: Alternative: • Filling disk space with catalyst particles (packed bed) PBR DR

  15. Overview • Our Main Task in this Project • WP 2.1: Reformer • WP 2.2: Post-Combustor • WP 2.3: Integration and Testing • Validation of Milestones • Next Steps

  16. WP 2.2: Post Combustor (PC) Purpose of PC: Catalytic oxidation of (toxic, flammable) exhaust gases • e.g. C4H10 + 6.5 O2 → 4 CO2 + 5 H2O • e.g. CO + 0.5 O2 → CO2 • Several studies in literature • Choice of catalyst and support: (Pt Ce0.5Zr0.5O2) • PC design similar to reformer (constraints: stack integration) • Composition of gas at inlet? • Modified product specification

  17. Milestones (MS) • MS @ month 12: first preliminary post-combustor demonstrator aiming for significant oxidation rate @ 600°C and stable for feeds of 0.02 to 0.5 g/h butane (fabrication: NTB, testing: LTNT) • Modified product specification (from 1 W to 2.5 W power output → Modified test rig) • Inlet gas composition not known (CO, CH4, C4H10 conversion in Fuel Cell?) • Reforming with disk reactor not yet satisfied • Catalyst particles are active (and already produced by LTNT)W. J. Stark, J. D. Grunwaldt, M. Maciejewski, S. E. Pratsinis, A. Baiker, "Flame-made Pt/ceria/zirconia for low-temperature oxygen exchange", Chem. Mater., 17 (13) 3352-3358 (2005). ongoing

  18. Overview • Our Main Task in this Project • WP 2.1: Reformer • WP 2.2: Post-Combustor • WP 2.3: Integration and Testing • Validation of Milestones • Next Steps

  19. WP 2.3: Integration and Testing • MS @ month 12: delivery of first reformer and post-combustor designs aiming for compatibility with heat exchanger and hot module processing (LTNT) • Final design: disk reactor • Initial specifications: dimensions determined • Altered Specifications: Dimensions to be determined   ongoing

  20. Overview • Our Main Task in this Project • WP 2.1: Reformer • WP 2.2: Post-Combustor • WP 2.3: Integration and Testing • Validation of Milestones • Next Steps

  21. Validation of Milestones and Deliverables • WP 2.1: Reformer • Month 12: reformer demonstrator with significant butane conversion rate @ 600°C and stable for feeds of 0.02 to 0.5 g/h butane incl. gas chromatography (fabrication: NTB, testing: LTNT)  • WP 2.2: Post-combustor • Month 12: first preliminary post-combustor demonstrator aiming for significant oxidation rate @ 600°C and stable for feeds of 0.02 to 0.5 g/h butane (fabrication: NTB, testing: LTNT) ongoing • WP 2.3: Integration and Testing • Month 12: delivery of first reformer and post-combustor designs aiming for compatibility with heat exchanger and hot module processing (LTNT)   • Previous Milestones and Deliverables: all fullfilled

  22. Summary of Results • Optimized butane reforming at low temperatures (PBR) • Ongoing butane reforming experiments with DR • Active catalyst particles for Post-Combustor • DR design for integration into hot module

  23. Overview • Our Main Task in this Project • WP 2.1: Reformer • WP 2.2: Post-Combustor • WP 2.3: Integration and Testing • Validation of Milestones • Next Steps

  24. Next steps (Year 2) NMW NMW NTB NTB • WP 2.1: High performance of disk reactor at T = 600°C: Butane conversion > 80%, hydrogen selectivity > 60% • (Coating in collaboration with NTB and NMW) • WP 2.1: Long-term stability tests of reformer at T = 600°C: Butane conversion loss < 10% (after 10 h steady state) • WP 2.2: Improved performance of post combustor: exhaust gas oxidation > 98% at T = 600°C and 0.7 g/h butane feed • (Inlet conditions for PC from NMW and EPFL) • WP 2.3: Integration of reformer and PC into hot module • (Constructal constraints from NTB and ZHW)

  25. Next steps (Year 3 / Year 4) NMW NMW NTB • WP 2.1: Optimized performance of disk reactor at T = 550°C: Butane conversion > 90%, hydrogen selectivity > 75% • (Inlet gas composition to NMW / EPFL) • WP 2.1: Start-up stability tests of reformer: Butane conversion loss < 10% (after 5 cycles from 25°C to 600°C) • WP 2.2: Optimized performance of PC at T = 550°C: CO conc. < 25 ppm (TLV, ACGIH). • (Operation parameters from NMW / EPFL, ZHW / NTB) • WP 2.2: Start-up stability tests of PC: CO conc. < 25 ppm (after 5 cycles from 25°C to 600°C)

  26. Questions ? • Optimized butane reforming performance at 600˚C! Results @ Month 6 Hydrogen Yield: Results @ month 12

  27. Validation of Milestones and Deliverables • WP 2.1: Reformer • Month 3: first reformer design available (LTNT) • Month 6: modelled and evaluated reformer based on 0.3 g/h butane in 2 cm3 with T max difference 50°C (reformer modelled for methane): effect of thermal conductivity of the reformer walls on the reformer process, microchannels coated with catalyst vs. porous catalyst (LTNT)   • WP 2.2: Post-combustor • Month 3: first preliminary post-combustor design available • Month 6: improved designs of post-combustors aiming for 0.3 g/h butane feed, fully oxidized in 1 cm3 @ 600°C and max. pressure drop of 3 Pa (LTNT)   • WP 2.3: Integration and Testing • Month 3: design of test rig available (LTNT) • Month 6: test rig for reformer and post-combustor for GPU performance incl. gas chromatograph (LTNT)   • Deliverables: • Month 3: reformer design from LTNT  NTB for evaluation • Month 6: final reformer design from LTNT  NTB for fabrication   • Deliverables: • Month 6: designs of post-combustor from LTNT  NTB for fabrication  • Deliverables: • Month 3: design from LTNT  NTB • Month 6:NTB samples  LTNT (P. Müller checks whether possible in month 6)  

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