Electrocatalytic reformer for synthesis gas production

Abstract

The invention relates to a method and devices for the chemical reaction of liquid, vapor or gaseous hydrocarbons with either water or water vapor and either air or oxygen, to produce a hydrogen-rich synthesized gas for use in fuel cells. In the process, the chemical reaction of the reactants takes place on the catalytically coated surface of a material that is electrically conductive, and as a consequence of the feeding an electrical voltage, directly heatable and consequently temperature-controllable.

1 . An apparatus for the chemical conversion of a hydrocarbon with at least water, to produce a hydrogen-rich synthesized gas for use in fuel cells, the apparatus including a component formed of an electrically conductive material and having a catalytically coated surface, whereby, in use, the component can be electrically heated, to promote endothermic reactions catalyzed by the catalytically coated surface.  
     
     
         2 . An apparatus as claimed in  claim 1 , wherein the component is formed from one of silicon and silicon carbide.  
     
     
         3 . An apparatus as claimed in  claim 2 , wherein the material of the component has a monolithic honeycomb structure.  
     
     
         4 . An apparatus as claimed in  claim 1 , wherein the material of the component comprises an aluminum-chrome-iron alloy.  
     
     
         5 . An apparatus as claimed in  claim 4  wherein the aluminum-chrome-iron alloy is formed as a wire mesh formed into a roll.  
     
     
         6 . An apparatus as claimed in  claim 3 , wherein the material of the component has porosity in the range 20-80%.  
     
     
         7 . An apparatus as claimed in  claim 6 , wherein the material of the component has porosity in the range 40-70%.  
     
     
         8 . An apparatus as claimed in  claim 6 , wherein the material of the component has an electrical resistance in the range 0.001 Ωcm to 10 MΩcm.  
     
     
         9 . An apparatus as claimed in  claim 2 , wherein the material of the component is provided in the form of a porous, lateral, flowable pipe.  
     
     
         10 . An apparatus as claimed in any one of claims  1 - 9 , wherein the catalytically coated surface of the component includes a catalyst comprising at least one metal selected from Group VII metals of the periodic table (Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, Pt), Cu and Zn.  
     
     
         11 . An apparatus as claimed in  claim 10 , wherein the catalyst comprises a combination of two or more of said metals.  
     
     
         12 . An apparatus as claimed in  claim 1 , wherein the component comprises an elongate, inner pipe, and wherein the apparatus includes an outer pipe enclosing the inner pipe and defining an annular chamber, thereby to form an electrocatalytic reformer element.  
     
     
         13 . An apparatus as claimed in  claim 12 , wherein the outer pipe is provided with a catalytic coating for promoting exothermal reactions of anode exhaust gas with at least one of air and oxygen.  
     
     
         14 . An apparatus as claimed in  claim 13  which includes a plurality of electrocatalytic reformer elements, a vessel enclosing the elements, a first port and a first manifold providing communication to the annular chambers of the electrocatalytic reformer elements, a second port and a second manifold providing communication to the interior of the inner pipes of the electrocatalytic reformer elements, a chamber around the electrocatalytic reformer elements, and third and fourth ports providing an inlet and an outlet for anodized exhaust gases around the electrocatalytic reformer elements.  
     
     
         15 . A method of chemically converting a hydrocarbon to generate a hydrogen-rich synthesized gas, the method comprising: 
 (a) Providing the hydrocarbon as one of a liquid, vapor and gas;    (b) Supplying water to at least one of the liquid and vapor state;    (c) Supplying the hydrocarbon and the water to an apparatus including at least one electrocatalytic reformer element having a component with a catalytically coated surface, whereby the hydrocarbon and the water are exposed to the catalytically coated surface;    (d) Passing electric current through the component, to heat the component and to provide heat for endothermic reaction of the hydrocarbon and the water.    
     
     
         16 . A method as claimed in  claim 15 , which includes supplying a mixture of water with one of air and oxygen.  
     
     
         17 . A method as claimed in  claim 15 , that includes measuring the resistance of at least one electrocatalytic reformer element, and determining the temperature from the measured resistance.  
     
     
         18 . A method as claimed in  claim 17 , which includes adjusting the electric current to maintain said at least one reformer element at a desired temperature, and adjusting the temperature in dependence upon anticipated changes in demand for converted hydrocarbon.  
     
     
         19 . A method as claimed in  claim 15 , which includes providing the component of the electrocatalytic reformer element as a porous component, and passing the hydrocarbon and the water through the porous component.  
     
     
         20 . A method as claimed in  claim 19 , which includes providing the component as a porous pipe, and forming the catalytically coated surface on exposed surfaces of the pipe.  
     
     
         21 . A method as claimed in  claim 20 , which includes passing the hydrocarbon and the water radially inwards from the outside to the inside of the pipe.  
     
     
         22 . A method as claimed in  claim 20 , which includes passing the hydrocarbon and the water radially outwards from the inside to the outside of the pipe.