Anthony AndersonDirector, Marketing & Business Development
2013 Hannover Messe Group Exhibit Hydrogen + Fuel Cells
April 11, 2013
Microlith® Fuel Reformer and Fuel Processor Systems
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
• Technologies : Microlith® Catalytic Reactors, RCL® Combustors Reforming: Syngas, H2, Chemicals, kW – MW scales
Sorption: Bio/Chem, Sulfur, trace contaminants Small engines: Tactical Power, UAV Combustion: Gas turbines, burners, augmentation, down-hole, Stirling Prototypes: BOP, Controls, packaging
• Established 1986; Privately held, Small Business; 39 employees; North Haven, CT
• Collaborators include: U.S. Govt., large & small corporations, universities, national labs.
• Develop advanced catalysts, reactors/systems; manufacture limited-volume prototypes
Precision Combustion, Inc.
38,000 sq ft facility
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
PCI Technology-Product-Application Space
Power
Fuel CellsAPUs/gensetVehicle/Ship
IC EnginesTactical Gensets
UXV Fuel Cells
Reformers for Industrial Systems
Combustion
Kitchen Burner
Stirling Burner
Fuel Cell Oxidizers
Catalytic Combustors
• Combustors• Steam generators
Air Cleaning
Oxidizers
Adsorbers
Other
H2 generation/ compact GTL
Catalytic ignitors
Chemicals manufacture
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
Microlith® Reactor Technology
Small, durable, catalytically coated metal mesh with very high surface area
PCI holds multiple patents on catalyst structure, reaction methods and apparatus
Continuous catalyst coating line with batched furnace and rigorous QA, QC in place
Microlith® Catalytic ReactorsUltra compact
Short contact timeRapid thermal response
High heat & mass transferHigh surface area/unit volume
Low cost
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
Microlith® Reactor Technology
Cells/in2
GSA (m 2/l)Channel Length (in)
Length to Diameter Ratio (L/d)Operating Temperature ( oC)
Frontal Open Area
4002.64
3.0 - 5.070 - 120
1050 - 120070
25006.3
0.0030.3
1050 - 120072
Microlith®Conventional Monolith
Monolith wall
Monolith wall
Monolith wall
Boundary layer formation
Mixing regions
Boundary layer formation
High surface area & high mass/high heat transfer capability at comparable pressure drop
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
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Comparison of Substrate Performance (Steady State Operation w. propylene in air at 350 C, vel. 1.5 m/s.)
2.54 cm(1”) long monolith 7 Microlith elements(Length = 0.11cm, 0.042”)
5.3 cm/s7620 cm2
75
77 cm/s568 cm2
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Equivalent conversion with 20-fold size reduction.
More Efficient Use of Catalyst Surface Area
Mass Transfer Coeff (kc)GSA
Observed Conversion (%)
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
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Rapid Thermal Response
0
100
200
300
400
0 2 4 6 8 10 12 14
Tem
pera
ture
(C)
Time (sec)
MonolithMicrolith®
• Lumped Capacitance Analysis (const. temp. fluid)• No contribution due to exothermic reactions• tc = mCp/hAt Microlith® = 0.12 sec; Monolith = 3.4 sec.
Fast Transient Response
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
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Benefits of Improved Mass Transfer
500
700
900
1100
1300
1500
1700
1900
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Selectivity
T ad
iaba
tic, C
TD analysis, f = 3.5, T inlet = 527oC
CH4 + 2 O2 CO2 + 2 H2O -192 kcal/m
CH4 + ½ O2 CO + 2H2 -8.5 kcal/m
0
5
10
15
20
25
30
35
40
0 1 2 3 4 5
axial position, mm
conc
entr
atio
n, %
700
750
800
850
900
950
1000
1050
1100
tem
pera
ture
, C
H2 O2CH4 COCO2 H2OT catalyst
phi v,m/s T max,C H2% CO% H2O% CO2% CH4% conv% H2_sel% CO_sel%3.4 2.6 1075 36.43 18.22 2.34 1.17 0.06 99.67 93.96 93.96
CH4 CPOX; Experimental Data
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
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Reforming (for Fuel Cells, H2 gen, Comb. Aug.)
1. Catalytic Partial Oxidation (CPOX)2 CH4 + O2 4 H2 + 2CO {H2O + CO2 - ∆H}
2. Catalytic Autothermal Reforming (ATR)
3 CH4 + O2 + H2O 7 H2 + 3 CO {H2O + CO2 - ∆H}
3. Catalytic Steam Reforming (CSR)
CH4 + H2O 3 H2 + CO {H2O + CO2 + ∆H}
PCI has ongoing programs in all these areas, using its Microlith® Technology
5 kWth DieselFor Automotive
5 MWth Nat. Gas
Fuel + Steam (CSR Inlet)
H2, CO
Fuel + Air (CTOX Inlet)
H2O, CO2
5 kWth & 1 MWth Diesel/JP-8 ATR, St. gen. S-trap, Injector
3 - 10 kWth Diesel/JP-8 SR, St. gen, Exo/Endo, Hi P.
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
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H2 Purification
• Water Gas Shift Reactor (WGSR)CO + H2O H2 + CO2 {CH4 - ∆H}
• Preferential Oxidation of CO (PROX)CO + ½ O2 {H2} CO2 {H2O - ∆H}
• Membrane Separation IntegrationPd/Ag/Polymer on metal/ceramic supports
• Pressure Swing Adsorption (PSA)H2 selective sorbents
PCI has ongoing programs in these areas
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
Commercial Applications
Aircraft APU Truck APU Marine APU
Fuel Cell Range Extenders RV APU Industrial Syngas
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
PCI innovation: Sulfur-tolerant Logistics Fuel Reformer
• Ultra-compact high efficiency reformer able to convert diesel, military fuels, alcohols, biofuels to sulfur-free syngas (H2+CO)
• Microlith design combination is uniquely compact, sulfur-tolerant and efficient
• Value added: We put the fuel in fuel cells®
– PCI reformer/fuel processing system allows SOFC fuel cells to use diesel/military fuels– With PCI WGS, allows HT-PEM fuel cells to use diesel/military fuels – With H2 separation technology, can produce high quality hydrogen from diesel/military fuels
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
Compared to other fuel processors, our solution offers
• Lower weight up to 3X!
• Smaller size up to 6X!
• Faster response • Lower pressure drop• Significantly reduced cost
Comparison with Other Options
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
Capable of Startup, load following, shutdown
PCI Designs/Supports Complete SOFC Integrated Systems
Fuel Processor
(ATR, injector, steam generator,
sulfur trap, igniter, fuel & water pump,
air blower, fuel/air/water
control)
SOFC
(Stack, cathode air blower,Power conditioning,
stack controller,AGB)
Reformate Flow
Control
Thermal balance
é
Fuel, Air, Water
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
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Reformer for 1 kWe SOFC Generator
5.5"
3.5"
• Reformer includes reforming catalyst, steam generator HEX, startup glow plug, & sulfur cleanup• Capable of producing SOFC-quality reformate from up to 3000 ppm S JP-8• Operates under water neutral conditions (low steam-to-carbon ratio) with logistic fuels & diesels
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
Reformer Subsystem + BOP
• 40 kWth reformer: weight ~17 kg (Reformer + Mixer/injector + Sulfur Trap) • Steady state parasitic power needs for 1-2 kWe: <100 We
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
5.0
5.3
6.4
5.6
17.3
ATR
Sulfur Trap
WGSR 5.3
6.4
5.6
17.3
6.6
5.3
6.4
5.6
17.3
ATR
Sulfur Trap
WGSR
25 kWth ATR w. fuel/air/steam injector, igniter, steam generating HX, sulfur trap, WGSR
Fuel Processor (HT-PEM/PEM)
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
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ATR Reformate Compositions(mole %, wet basis)
ATR HEX Sulfur TrapF/A/SAtomizer
• Reforming efficiency (LHV reformate/LHV feed) = ~85%• Sulfur removal to <1 ppm• Current PCI’s target for coke precursors (i.e., C2s and C3s) is <50 ppmv total
WGSR
Fuel S/C O/C H2O H2 N2 CO CO2 CH4 C2 + C3 S
JP-8 (Equil) 0.90 0.95 12.1 29.5 37.5 15.3 5.7 0.01 -
JP-8 (Exptl) 0.90 0.95 12.7 28 37.7 16.3 5.4 0.16 <50 ppm <1 ppm
After WGSR 10-15 35 39 <1 * 12-14 0.3
[*: Fn of St/C]
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
ATR Scale-up: 1 MWth ATR System
Modular 250 kWe Fuel Processing System consisting of fuel/air/steam injector, ATR steam generator hex, sulfur clean-up, controls, pumps, blowers, filters,
sensors.
63”
48”
ATR
Igniter
SteamGenerator
Trim HEX
Desulf.
W GSR
Injector
63”
48”
ATR
Igniter
SteamGenerator
Trim HEX
Desulf.
W GSR
Injector
6.8
ft
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
1 MWth Microlith® Autothermal Reformer to reform VOC compounds from process waste streams
Scale-up: 1 MWth VOC Reformer
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
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CPOX Scale-up: 5 MW(th) Natural Gas Processor
• Performance testing successfully completed.• 1000 hrs of sub-scale durability completed (Target 8000 hrs).
5 MWth reactor to reform natural gas to produce syngas
2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
7 – 10 kWth CSR for Diesel, Natural Gas
• Low peak temperatures• Sulfur tolerance (~5 ppm)• High Heat Flux Compact size• Capable of high pressure operation• Achieves thermodynamic efficiency at Low S/C ratios
Catalytic burner instead of flame-stabilized burner increases thermal uniformity, distribution, durability & control.
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2013 Hannover Messe Group Exhibit Hydrogen + Fuel CellsApril 11, 2013
Come See Us!
Precision Combustion, Inc.Booth# D76/1We put the fuel in fuel cells®
Tony AndersonDirector, Marketing & Business Development
[email protected]+1 203-287-3700 Ext.290
Kevin BurnsPresident
[email protected]+1 203-287-3700 Ext. 213
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