BACKGROUND OF THE INVENTION [0002] Fuel cell systems have been proposed as power sources for a varying number of applications, including mobile, vehicular applications.

Generally, a fuel cell system includes a fuel cell stack that uses hydrogen to produce an electrical current for powering an external device. The hydrogen may be supplied to the fuel cell stack directly from a hydrogen source.

However, because of complications associated with storage of a pure hydrogen source within a vehicle, it is more practical that the hydrogen is provided through the reformation of a hydrocarbon fuel. To this end, an auto-thermal reformer is implemented for reforming the hydrocarbon fuel to produce a reformate stream having a hydrogen component.

[0003] Traditionally, vaporized fuel, water (as steam) and air are provided as a mixture from a mixing unit to the auto-thermal reformer. The fuel and water are converted from liquid to vapor form through a vaporization process performed within either independent or combined vaporizers.

Typically, a combustor is provided for producing hot combustion gases to sufficiently heat the vaporizer (s), enabling the vaporizer (s) to vaporize the liquid fuel and water channeled therethrough. The vaporized fuel and water (now steam) are channeled into a mixing unit for mixture with air, and further channeled into the auto-thermal reformer for reformation.

[0004] Such traditional vaporization systems include significant disadvantages. For example, because the vaporizing energy is provided by an external component (i. e. combustor), modulation of the fuel flow, as a function of system demand, is limited. In other words, the turndown dynamics of

traditional systems is limited, whereby the variation of mass flux through the vaporizer and mixing units is unable to achieve the required turndown ratio in response to rapid total mass flux through the auto-thermal reformer (as a function of power demand). Another disadvantage of such systems is that soot tends to form within the mixing unit, thereby inhibiting the proper operation of the system. Further, the operational parameters (i. e. temperatures greater than 500°C) of traditional vaporization systems may result in auto-ignition of the mixture, prior to entering the auto-thermal reformer. Ignited mixtures reaching the auto-thermal reformer can damage the catalyst therewithin and results in inefficient, undesirable reformation reactions. Presently, to avoid auto-ignition a complex control strategy for volume flows into the auto-thermal reformer is employed. This increases the cost and complexity of the fuel cell system.

[0005] It is known in the art to implement a cold-flame vaporizer in a system where fuel is oxidized to enable partial conversion of the fuel.

However, such applications rely on significant pre-heating of input streams, coupled with strict control of residence time in a reaction chamber, flow control of inerts or transfer of heat to the reaction chamber heat sink to control fuel conversion and prevent auto-ignition. This type of system is disclosed in German Publication No. DE 198 60 308. These strict control requirements pose disadvantages, particularly in cases where fuel conversion forms a part of a larger system, where cost, complexity, operable flexibility and system integration issues are important.

[0006] Therefore, it is desirable in the industry to provide an improved vaporizer and vaporization process that alleviates the disadvantages of traditional vaporizers and processes.

SUMMARY OF THE INVENTION [0007] Accordingly, the present invention provides a fuel reformer for producing a reformate stream for utilization in a fuel cell. The fuel reformer includes a fuel inlet for supplying a flow of liquid fuel into the fuel reformer, an oxidizer inlet for supplying a flow of oxidizer into the fuel reformer, a vaporizer for partially oxidizing the flow of liquid fuel to generate heat for vaporizing a

remaining flow of the liquid fuel for producing vaporized fuel. The vaporizer operates within an oxygen to carbon, molar ratio range of 0.5 to 2.3. That is, in a range from 0.5 mole oxygen for every 1 mole of carbon to 2.3 moles of oxygen for every 1 mole of carbon. The fuel reformer further includes an auto- thermal reformer in fluid communication with the vaporizer for reforming the vaporized fuel to produce the reformate stream. Additionally, the fuel reformer includes a steam inlet for supplying a flow of saturated steam into the fuel reformer, wherein the flow of saturated steam is superheated utilizing the generated heat, whereby the vaporizer operates within a steam to carbon, molar ratio range of 1.5 to 3.0. That is, 1.5 moles of steam (H20) for every 1 mole of carbon, up to 3.0 moles of steam for every 1 mole of carbon. It is further preferred that the vaporizer operates within a pressure range of approximately 1.5 to 3.0 bar-gauge.

[0008] The present invention further provides a method of reforming a liquid fuel to a reformate stream, including the steps of: providing a cold-flame vaporizer, supplying a flow of the liquid fuel and a flow of oxidizer into the cold- flame vaporizer, controlling an oxygen to carbon, molar ratio within the cold- flame vaporizer within a range of 0.5 to 2.3, oxidizing a portion of the liquid fuel within the cold-flame vaporizer for generating heat, the heat vaporizing the remaining liquid fuel, thereby producing vaporized fuel, and reforming the vaporized fuel within an autothermal reformer. The present invention further anticipates the steps of supplying a flow of saturated steam into the cold-flame vaporizer, superheating the flow of saturated steam utilizing energy from the generated heat, and controlling a steam to carbon, molar ratio within said cold- flame vaporizer within a range of 1.5 to 3.0. It is also preferred to control a pressure within the cold-flame vaporizer within a range of approximately 1.5 to 3.0 bar-gauge.

[0009] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS [0010] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: [0011] Figure 1 is a schematic view of a fuel cell system implementing a preferred fuel processing sub-system having a combination cold-flame vaporizer/auto-thermal reformer in accordance with the principles of the present invention; [0012] Figure 2 is a schematic view of a traditional system for vaporizing fuel for reformation in an auto-thermal reformer; [0013] Figure 3 is a schematic view of an alternative fuel processing sub-system implementing the cold-flame vaporizer and the auto-thermal reformer; [0014] Figure 4 is a graph detailing temperature characteristics within an outlet of a traditional vaporizer; [0015] Figure 5 is a graph detailing temperature characteristics within an outlet of the cold-flame vaporizer; and [0016] Figure 6 is a graph comparing volume percentages of reformate stream components produced through an ideal reformation process and volume percentages of reformate stream components produced through a combined cold-flame vaporization and reformation process.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS [0017] The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

[0018] With reference to Figure 1, an exemplary fuel cell system 10 is shown. The system 10 includes a fuel tank 12 for supplying a hydrocarbon fuel, such as, but not limited to gasoline (C745H14. 5), to a fuel processing sub- system 14 including a combination cold-flame vaporizer and auto-thermal reformer constructed in accordance with the principles of the present invention.

The sub-system 14 includes a cold-flame vaporizer (CFV) 14a in fluid

communication with an auto-thermal reformer (AR) 14b. Further, a saturated steam source 16 and an air source 18 are also included for respectively providing saturated steam and air to the CFVAR 14. Air is further supplied to a fuel cell stack 20, as described in further detail hereinbelow, and is driven through the system by a compressor 22. An air pre-heater 23 is also provided for preheating the air supplied to the sub-system 14. It is anticipated that the pre-heater 23 is a conventional pre-heater, including, but not limited to, an electric pre-heater.

[0019] The auto-thermal reformer 14b disassociates the hydrocarbon fuel using steam and air that react with the hydrocarbon fuel for producing a hydrogen-rich reformate. In an ideal auto-thermal reformer, two reactions occur: partial oxidization (POx) and steam reforming (SR). The heat balance of these processes is preferably neutral, whereby the partial oxidization reaction produces heat used by the steam reforming reaction. These reactions are provided as: POx : CnHm + (n/2) 02 nCO + (m/2) H2 SR: CnHm + nH20 nCO + (n + m/2) H2 [0020] As indicated by the above equations, an ideal reformation process yields a reformate gas comprising hydrogen and carbon monoxide.

However, a practical reformation process yields additional by-products including carbon dioxide, nitrogen and water. The efficiency of the auto- thermal reformer 14b is a function of the H2 yield and is dependent upon the temperature at which the inlet mixture (i. e. fuel, steam and air) enters the auto- thermal reformer 14b. If the inlet temperature of the mixture is less than 150°C, less H2 and CO are formed and thus, the efficiency is low. The efficiency of the auto-thermal reformer 14b reaches a peak at an inlet mixture temperature 350°C, above which no substantial efficiency is achievable.

[0021] Even operating at a high efficiency, the carbon monoxide content of the reformate stream is generally of too high a level, whereby use in the fuel cell stack 20 would result in the fuel cell stack 20 being poisoned.

Therefore, from the auto-thermal reformer 14b, the produced reformate stream

flows to a water-gas-shift (WGS) reactor 24 and further into a preferential oxidization (PROX) reactor 26 for reducing the carbon monoxide content to an acceptable level.

[0022] Within the WGS reactor 24, water (as steam) is added to the reformate provided from the auto-thermal reformer 14b in the presence of a suitable catalyst, thereby lowering its temperature and increasing the steam to carbon (S/C) ratio therein. A higher S/C ratio serves to lower the carbon monoxide content of the reformate according the following ideal shift reaction: CO + H20-- C02 + H2. In this manner, the amount of carbon monoxide is reduced, however, not enough for the reformate stream to be safe for use in the fuel cell stack 20.

[0023] The PROX reactor 26 is provided for further reducing the carbon monoxide content to an acceptable level for use in the fuel cell stack 20.

The reformate stream exiting the WGS reactor 24 enters the PROX reactor 26 where it is catalytically reacted with oxygen, supplied in the form of air from the air source 18, according to the following reaction: CO + 02- C02. The reformate stream then flows from the PROX reactor 26 to the fuel cell stack 20 for generating electric energy.

[0024] With reference to Figure 2, a traditional fuel processing sub- system 30 is shown, generally including independent water and fuel vaporizers 32,34, respectively, a mixing unit 36 and an auto-thermal reformer 38. The traditional sub-system 30 further includes a combustor (not shown) supplying hot combustion gases to the vaporizers 32,34 for providing vaporizing heat energy. As noted by way of background, the traditional sub-system 30 includes multiple components, requiring significantly more packaging space within a vehicle.

[0025] As discussed by way of background, traditional vaporization and mixing systems, such as the sub-system of Figure 2, include significant disadvantages. With reference to Figures 1 and 3, the present invention provides sub-systems 14,14', respectively, for alleviating these disadvantages.

In particular, the present invention includes the cold-flame vaporizer 14a for vaporizing fuel and superheating the saturated steam. The cold-flame

vaporizer 14a relieves the need for the combustor, as explained in further detail below. Further, the cold-flame vaporizer 14a acts to sufficiently mix the vaporized fuel and steam, thereby relieving the need for the independent mixer.

As detailed in Figure 3, the cold-flame vaporizer 14a may be independent of and in fluid communication with the auto-thermal reformer 14b. However, as detailed in Figure 1, it is preferred that the cold-flame vaporizer 14a and the auto-thermal reformer 14b be incorporated into a single unit. In this manner, a reduction in overall system size is achievable.

[0026] The cold-flame vaporizer 14a intakes air, fuel and saturated steam for vaporizing the fuel and superheating the saturated steam therein.

The cold-flame vaporizer 14a combusts or at least partially (oxidizes) a portion of the fuel, approximately 3-5% by volume, and generally less than 10% by weight. In particular, the pre-vaporized mixture within the cold-flame vaporizer 14a is generally fuel rich with a relative volume of air below a flammability limit of the overall mixture. In this manner, there is insufficient air to enable combustion of the entire volume of mixture. This oxidization process provides sufficient heat energy to vaporize the remaining fuel and superheat the incoming saturated steam, for mixture with the air therein. In order to achieve oxidization of a limited volume of fuel, the cold-flame vaporizer 14a must maintain specific environmental conditions therewithin, as described in further detail herein.

[0027] Generally, the cold-flame vaporizer 14a is characterized by partial oxidization of a fuel/air mixture using a low temperature flame, within a specified temperature range. This temperature range is provided as approximately 310°C to 500°C. Below 310°C no oxidization reaction is possible, however, above 500°C auto-ignition of the mixture within the cold- flame vaporizer 14a would occur. The partial oxidization reaction is exothermic and entails partial Os consumption and partial fuel conversion. The heat released from the partial oxidization reaction is used within the cold-flame vaporizer 14a to vaporize the remaining fuel and superheat the saturated steam therewithin. It should be noted that the cold-flame oxidization reaction is kinetically limited, whereby a temperature increase is achieved without ignition

of the resultant fuel/air mixture. As a result, the modulation capability is not limited and a broad range of turndown ratios are achievable. Thus, the temperature of the resultant mixture is practically constant, regardless of capacity variation through the cold-flame vaporizer 14a. As discussed above, efficient reformation within the auto-thermal reformer 14b requires the resultant mixture from the cold-flame vaporizer 14a to be at a temperature greater than 350°C. Because the temperature of the outlet mixture of the cold-flame vaporizer 14a achieves this temperature, it is practical to integrate the cold- flame vaporizer 14a and the auto-thermal reformer 14b in a single unit.

Further, the temperature and consistency in temperature of the resultant mixture enable optimized reformation within the auto-thermal reformer 14b.

[0028] As mentioned above, specific environmental parameters need be met in order for the cold-flame vaporizer 14a to operate within the above- described temperature range. These environmental parameters include: oxygen to carbon ratio (O/C), steam to carbon ratio (S/C) and pressure. The O/C and S/C ratios are molar ratios. Molar ratios are preferable over volumetric ratios as they are independent of other systems parameters (e. g. pressure and temperature). The pressure must be below the flammability limit of the overall mixture, at the selected O/C ratio. That is, the pressure is not sufficient to cause auto-ignition of the mixture. Pressure units herein are expressed as bar-g (bar gauge). Through theoretical calculation and experimental confirmation, the present invention provides the parameters as follows : O/C = 0. 5-2.3 S/C = 1. 5-3.0 Pressure = 1. 5-3. 0 [0029] Variation from these parameters, specifically the O/C and S/C ratios, may result in either suppression of the reaction or increased temperature. Suppression of the reaction results from flooding of the auto- thermal reformer 14b and increased temperature could cause auto-ignition of the vaporized mixture.

[0030] The characteristic temperature of the cold-flame is defined by the limited reaction kinetics, whereby the oxidization reaction stabilizes under the defined parameters of O/C, S/C and pressure. An increase in pressure within the cold-flame vaporizer 14a results in a temperature increase therewithin. Similarly, a temperature increase is achieved through a reduction in the O/C ratio, whereby the partial pressure of the hydrocarbons (fuel) increases the overall pressure. A temperature reduction is seen through an increase in the S/C ratio, whereby the partial pressure of the hydrocarbons (fuel) decreases the overall pressure. In this manner, the environmental parameters are linked. It should also be noted that the characteristic temperature of the cold-flame vaporizer 14a is also dependent upon the flow within the cold-flame vaporizer 14a. For example, implementation of a recirculation structure (not shown), results in lower cold-flame temperatures.

Although the O/C and S/C ranges provided by the present invention are somewhat fixed for maintaining the cold-flame at a functional temperature, it is anticipated that the pressure may be variable above or below the indicated range by approximately 10 to 30%.

[0031] Operation of the cold-flame vaporizer 14a is not only dependent upon the operating parameters discussed above, but also the temperature at which the air enters the cold-flame vaporizer 14a. The air pre- heater 23 controls the inlet temperature of the air into the cold-flame vaporizer 14a for ensuring the cold-flame reaction. The temperature of the fuel entering the cold-flame vaporizer 14a can be anywhere between ambient and its boiling point.

10032] As described above, the cold-flame vaporization process partially oxidizes the fuel. The partial oxidization of the fuel is supported through a simplified heat balance for the cold-flame vaporizer 14a. The heat within the cold-flame vaporizer 14a is dividable into three heat fluxes : overheating of air and steam from inlet to outlet temperature (Q1), estimation of heat loss to the periphery considering the outlet temperature without a reaction and vaporization (Q2) and heating of the fuel from boiling to outlet temperature (Q3). The heat fluxes are respectively represented by the following equations:

Q1-mairCp, air'+'msteamCp, steam) (Toutlet-Tinlet) Q2 v (mairCp, air'+'f1"lsteamCp, steam) (Tinlet-Toutlet, wo reaction) Q3 = mfuel Cp, fuel, liq (Tboiling-Tinlet fuel) + r0 + Cp, fuel, vapor (Toutlet-Tboiling)] wherein: Q = heat flowrate m = mass flowrate T = temperature cp = specific heat ro = heat of vaporization [0033] Further, the thermal power of a specified fuel is provided as: Qfuel, in = nfuel, inLHVfuel wherein: n = molar flowrate LHV = lower heating value [0034] Dividing the sum of the three heat fluxes by the thermal power of the fuel gives the oxidization rate (U) of the cool-flame reaction. Expressed in a percentage, the oxidization rate (U) is provided as: U = [ (Ql+Q2+Q3)/Qfuel, in] x 100% [0035] The first and third heat fluxes relate to the cold-flame reaction independent of the specifics of the cold-flame vaporizer 14a within which the reaction occurs. Further, the first and third heat fluxes are dependent upon the inlet conditions and the thermodynamic properties of air, steam and the particular fuel. The second heat flux represents heat loss to the periphery and is dependent upon the particular characteristics of the cold-flame vaporizer 14a <BR> <BR> (e. g. insulation, geometry, etc. ). Therefore, although the second heat flux is not measurable in the functioning apparatus, it influences fuel conversion therein and must be considered.

[0036] With particular reference to Figures 4 and 5, a temperature comparison is provided between a conventional vaporizer and the cold-flame vaporizer 14a. For each figure, the temperature of the respective outlet of the vaporizer, to the auto-thermal reformer, was measured at four points. As shown, the conventional vaporizer includes a non-uniform temperature profile achieving a temperature in the auto-ignition range (i. e. above 500°C). In comparison, the cold-flame vaporizer includes a uniform temperature profile achieving a temperature above the required auto-thermal temperature (350°C), while remaining sufficiently below the auto-ignition temperature. Further, the temperature variation across the outlet signifies the quality of vaporization and mixture therein, whereby a uniform temperature across the outlet indicates a higher quality of vaporization and mixing. The quality of H2 production within the auto-thermal reformer 14b is dependent upon the efficiency of the auto- thermal reformer 14b. As mentioned previously, the efficiency of the auto- thermal reformer 14b is dependent upon the temperature at which the reactants enter the auto-thermal reformer 14b.

[0037] With reference to Figure 6, a comparison of resultant reformate components is provided as between a theoretical auto-thermal reformation process and an auto-thermal reformation process implementing cold-flame vaporization. The theoretical auto-thermal reformation process is based upon an adiabatic, ideal auto-thermal reformation process for achieving optimal volume concentrations for the reformate components. The cold-flame vaporization process was performed for gasoline (C745H14. 5) with ONC = 1.0, S/C = 1. 6 and pressure = 1. 8 bar-g. The significant component is the concentration of H2, as H2 is desired for use in the fuel cell stack 20. As shown, the ideal theoretical value for H2 is given as 26.3% while the auto-thermal reformation process, implementing the cold-flame vaporization process, achieves a value of 26.7%. Thus, it has been shown that implementation of the cold-flame vaporizer 14a enables achievement of optimal H2 concentration within the resultant reformate stream.

[0038] As described above, the present invention combines the cold- flame vaporizer 14a and the auto-thermal reformer 14b into a single unit (see

Figure 1). In this manner, the functions of vaporizing, mixing and reforming are combined in the single unit, thereby reducing the overall volume and weight of the system 10. Further, the present invention provides specific operational parameters, within which the cold-flame vaporizer 14a must operate to ensure the cold-flame reaction for transient applications. Controlling the O/C, S/C and pressure parameters within the single unit enables control of the transient reformation process for reducing the risk of catalyst damage and unwanted reactions therewithin.

[0039] As described hereinabove, the present invention establishes concentration and pressure ranges to enable vaporization of fuel and superheating of saturated steam over a wide range of flow rates while preventing auto-ignition. Further, the ranges so established by the present invention enable the supply of an essentially homogeneous reformate stream to the auto-thermal reformer 14b at a desired temperature for optimized reformation therein. More specifically, the selected O/C, S/C, and pressure ranges permit operation over a system turndown ratio of at least 5, desirably at least 10, preferably 20, and most preferably 30. As used herein, the term turndown ratio refers to the modulation capability expressed as mass flow per unit of time of the total flows to the vaporizer. As such, when the inputs are an oxidant and a hydrocarbon fuel, the turndown ratio is based upon the mass flow rates of the oxidant and the hydrocarbon fuel. When the inputs are an oxidant, a hydrocarbon fuel and saturated steam (which is superheated), the turndown ratio is based on the mass flow rates of the oxidant, the hydrocarbon fuel and the saturated steam. A turndown ratio of 30 or 30: 1, for example, means that on the basis of one mass flow unit per time, the maximum flow is up to 30 times as great as the minimum. Thus, the system is operable to supply the reformer under transient conditions where the total mass flow rate to the vaporizer varies by a factor of up to 30, and hence, such vaporizer outlets supplied to the reformer has a mass flow rate which also varies by a factor of 30.

[0040] Although the present invention, as described herein, includes vaporizing liquid fuel and superheating saturated steam within the cold-flame vaporizer 14a, it is expected that water forms a part of the input supplied to the

vaporizer 14a, for vaporization therein, since equilibrium exists between liquid water and water vapor as determined by pressure and temperature.

Accordingly, the heat generated through oxidization is used to vaporize any combination of the following : vaporize liquid fuel, vaporize any liquid water to steam, and superheat any steam. The inlet stream of water in both liquid and vapor form must be sufficient to provide a resultant S/C ratio within 1.5 to 3.0, as discussed in detail hereinabove.

[0041] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.