Catalytic system for converting liquid fuels into syngas

Abstract

The present invention is a method and a system for the gasification of a liquid fuel and includes providing a supply of a liquid fuel and an oxidant, atomizing the liquid fuel and mixing it with the oxidant, catalytically reacting the fuel oxidant mixture, providing an ignition source for initiating the catalytic reaction, positioning a heat exchanger in proximity with the catalytic bed, and producing steam which can be fed back into the system thereby eliminating the need for a vaporizer. A hydrocarbon fuel can be mixed with oxygen, as a constituent of air, preferably forming a fuel rich fuel air mixture that passes through a catalytic reactor having an ultra-short channel length metal monolith substrate.

1 . A method for gasification of a liquid fuel comprising: 
 a) providing a supply of a liquid fuel;    b) providing a supply of an oxidant;    c) providing a supply of water;    d) atomizing the liquid fuel;    e) mixing the atomized fuel with the oxidant;    f) catalytically reacting the fuel oxidant mixture creating reaction products;    g) providing an ignition source for initiating the catalytic reaction;    h) positioning a heat exchanger proximate to the catalytic reactor;    i) transferring heat from the reaction products to the water to produce steam; and    j) mixing the steam with the atomized fuel and the oxidant.    
     
     
         2 . The method of  claim 1  wherein the liquid fuel comprises hydrocarbons.  
     
     
         3 . The method of  claim 1  wherein the oxidant is a constituent of air.  
     
     
         4 . The method of  claim 1  wherein the step of mixing the atomized fuel with the oxidant further comprises forming a fuel rich fuel oxidant mixture.  
     
     
         5 . The method of  claim 1  wherein the step of catalytically reacting the fuel oxidant mixture includes providing a catalytic reactor comprising an ultra-short channel length reactor substrate.  
     
     
         6 . The method of  claim 5  wherein the step of providing a catalytic reactor further comprises providing a plurality of the substrates thereby providing void volumes in random order.  
     
     
         7 . The method of  claim 5  wherein the step of providing a catalytic reactor further comprises providing a catalyst on at least a portion of the substrate, the catalyst comprising one of the metals of group VIII of the periodic system of elements.  
     
     
         8 . The method of  claim 5  wherein the substrate is provided in a coiled configuration.  
     
     
         9 . The method of  claim 8  wherein the substrate is mounted to avoid bypass of the substrate by the fuel oxidant mixture.  
     
     
         10 . The method of  claim 1  wherein the step of providing an ignition source for initiating the catalytic reaction further comprises providing a glow plug.  
     
     
         11 . The method of  claim 1  wherein the step of catalytically reacting the fuel oxidant mixture includes vaporizing and partially oxidizing the fuel oxidant mixture.  
     
     
         12 . The method of  claim 1  including the additional steps of: 
 j) positioning a sulfur removal bed proximate to the heat exchanger; and    k) passing the reaction products through the sulfur removal bed.    
     
     
         13 . A system for gasification of a liquid fuel comprising: 
 a) a supply of a liquid fuel;    b) a supply of an oxidant;    c) a supply of water;    d) a fuel nozzle for atomizing the liquid fuel;    e) a mixing region for mixing the atomized fuel with the oxidant;    f) a catalytic reactor for catalytically reacting the fuel oxidant mixture thereby creating reaction products;    g) an ignition source for initiating the catalytic reaction; and    k) a heat exchanger positioned proximate to the catalytic reactor for producing steam.    
     
     
         14 . The system of  claim 13  wherein the liquid fuel comprises hydrocarbons.  
     
     
         15 . The system of  claim 13  wherein the oxidant is a constituent of air.  
     
     
         16 . The system of  claim 13  wherein the mixing region further comprises forming a fuel rich fuel oxidant mixture.  
     
     
         17 . The system of  claim 13  wherein the catalytic reactor comprises an ultra-short channel length reactor substrate.  
     
     
         18 . The system of  claim 17  wherein the catalytic reactor further comprises a plurality of the substrates thereby providing void volumes in random order.  
     
     
         19 . The system of  claim 17  wherein the catalytic reactor further comprises a catalyst on at least a portion of the substrate, the catalyst comprising one of the metals of group VIII of the periodic system of elements.  
     
     
         20 . The system of  claim 19  wherein the substrate defines a coiled configuration.  
     
     
         21 . The system of  claim 20  wherein the substrate is mounted to avoid bypass of the substrate by the fuel oxidant mixture.  
     
     
         22 . The system of  claim 13  wherein the ignition source comprises a glow plug.  
     
     
         23 . The system of  claim 13  further comprising a sulfur removal bed positioned proximate to the heat exchanger.  
     
     
         24 . A system for gasification of a liquid fuel comprising: 
 a) a supply of a liquid fuel;    b) a supply of an oxidant;    c) a supply of water;    d) means for atomizing the liquid fuel;    e) mixing the atomized fuel with the oxidant;    f) means for catalytically reacting the fuel oxidant mixture and creating reaction products;    g) means for initiating the catalytic reaction;    h) means for transferring heat from the reaction products to the water to produce steam; and    i) mixing the steam with the atomized fuel and the oxidant.    
     
     
         25 . The system of  claim 24  wherein the means for atomizing the liquid fuel comprises a fuel nozzle.  
     
     
         26 . The system of  claim 24  wherein the means for mixing the atomized fuel with the oxidant further comprises a means for forming a fuel rich fuel oxidant mixture.  
     
     
         27 . The system of  claim 24  wherein the means for catalytically reacting the fuel oxidant mixture comprises a catalytic reactor that comprises an ultra-short channel length reactor substrate.  
     
     
         28 . The system of  claim 27  wherein the catalytic reactor further comprises a plurality of the substrates thereby providing void volumes in random order.  
     
     
         29 . The system of  claim 27  wherein the catalytic reactor further comprises a catalyst on at least a portion of the substrate, the catalyst comprising one of the metals of group VIII of the periodic system of elements.  
     
     
         30 . The system of  claim 27  wherein the substrate defines a coiled configuration.  
     
     
         31 . The system of  claim 30  wherein the substrate is mounted to avoid bypass of the substrate by the fuel oxidant mixture.  
     
     
         32 . The system of  claim 24  wherein the means for an ignition source for initiating the catalytic reaction comprises a glow plug.