Fast light-off catalytic reformer

Abstract

A fast light-off catalytic reformer and method includes at least one preferably substantially cylindrical reactor tube having an inlet for receiving a flow of fuel and a flow of air, a reforming catalyst disposed within the reactor tube for converting the fuel and air to a reformate stream, and an outlet for discharging the produced reformate stream. An ignition device disposed within the reactor tube initiates an exothermic reaction between the fuel and air. Heat generated thereby provides fast light-off of the reforming catalyst. An associated control system selects fuel and air flow delivery rates and operates the ignition device to achieve fast light-off of the reforming catalyst at start-up and to maintain the catalyst at a temperature sufficient to optimize reformate yield. The rapid production of high yields of reformate is particularly suitable for use in an on-board reforming strategy for meeting SULEV emissions with spark-ignition engines, especially with larger, higher emitting vehicles.

1 . A fast light-off catalytic reformer comprising: 
 a catalytic reformer characterized by at least one reactor tube, said reactor tube having an inlet in a first end for receiving a flow of fuel and a flow of air, a reforming catalyst disposed within said reactor tube for converting said fuel and said air to a reformate stream, and an outlet in a second end for discharging said reformate stream;    an ignition device disposed within said reactor tube for initiating an exothermic reaction between said fuel and said air and using heat generated thereby to provide fast light-off of said reforming catalyst; and;    a control system for selecting fuel and air flow rate and operating said ignition device so as to achieve fast light-off of said reforming catalyst at start-up and to maintain said catalyst at a temperature sufficient to optimize reformate yield.    
     
     
         2 . The reformer of  claim 1 , wherein said ignition device disposed within said reactor tube is located upstream of said reforming catalyst, within said reforming catalyst at the front face of said reforming catalyst, or within said reforming catalyst at the rear face of said reforming catalyst.  
     
     
         3 . The reformer of  claim 1 , wherein said ignition device comprises a catalytic substrate or a non-catalytic substrate for receiving electric current from a voltage source, a spark plug, a glow plug, or a combination thereof.  
     
     
         4 . A power generation system employing a fast light-off reformer comprising: 
 a catalytic reformer characterized by at least one reactor tube, said reactor tube having an inlet in a first end for receiving a flow of fuel and a flow of air, a reforming catalyst disposed within said reactor tube for converting said fuel and said air to a reformate stream, and an outlet in a second end for discharging said reformate stream;    an ignition device disposed within said reactor tube for initiating an exothermic reaction between said fuel and said air and using heat energy generated thereby to provide fast light-off of said reforming catalyst;    a control system for selecting fuel and air flow rate and operating said ignition device so as to achieve fast light-off of said reforming catalyst at start-up and to maintain said catalyst at a temperature sufficient to optimize reformate yield; and    a power generation system operating at least partially on reformate fueling, said power generation system having a fuel inlet in fluid communication with said reformer outlet.    
     
     
         5 . The fast light-off reformer-power generation system of  claim 4 , wherein said power generation system is an engine, a spark ignition engine, a hybrid vehicle, a diesel engine, a fuel cell, a solid oxide fuel cell, or a combination thereof.  
     
     
         6 . A fast light-off reforming method comprising: 
 supplying a flow of fuel and a flow of air to a catalytic reformer, said catalytic reformer characterized by at least one reactor tube having an inlet for receiving said flow of fuel and air, a reforming catalyst disposed within said reactor tube for converting said flow of fuel and air to a reformate stream, and an outlet for discharging said reformate stream;    igniting said fuel and air within said reactor tube to rapidly heat said reforming catalyst with heat energy generated thereby; and    controlling said fuel and air supply and said igniting so as to achieve fast light-off of said reforming catalyst at start-up and to maintain said reforming catalyst at a temperature sufficient to optimize reformate yield.    
     
     
         7 . The method of  claim 6 , wherein said igniting is with an ignition device selected from the group consisting of a catalytic or non-catalytic substrate for receiving an electric current, a spark plug, a glow plug, or a combination thereof.  
     
     
         8 . The method of  claim 7 , wherein said substrate is wire or gauze.  
     
     
         9 . The method of  claim 6 , further comprising: 
 fueling a power generation system at least partially with said reformate stream.    
     
     
         10 . The method of  claim 9 , wherein said power generation system is an engine, a spark ignition engine, a hybrid vehicle, a diesel engine, a fuel cell, a solid oxide fuel cell, or a combination thereof.