Highly Integrated Steam Reforming Fuel Processor with Condensing Burner Technology for Maximised Electrical Efficiency of CHP-PEMFC Systems

Abstract

Compact fuel processors using natural gas, LPG and biogas for μCHP fuel cell systems have been developed at ZBT for over 10 years. The technology, based on steam reforming, includes a reformer and a WGS reactor, a water evaporator, heat exchangers and a fuel/anodic offgas burner integrated in an insulated housing. For coupling with a LT-PEMFC today an external preferential oxidation or methanation is added. A HT-PEMFC can be coupled directly to the fuel processor at a temperature level of 160°C. It is discussed that HT-PEMFC systems can exceed the electrical efficiency of LT-PEMFC systems up to five percentage points because of the integration of high quality heat from the fuel cell cooling cycle. In process simulations with AspenPlus® this efficiency advantage could be confirmed. But further investigations concerning heat integration showed for both systems the advantage of using the condensation enthalpy of the flue gas provided by the system burner. This gain in energy offers the opportunity to realise burner operation only with anodic offgas, without additional fuel firing. This study shows the use of condensing burner technology in the fuel processor in comparison of integrating HT-PEMFC heat and/or the use of conventional low-temperature burner technology. For comparison the system boundaries and efficiencies were clearly determined. Heat sources and sinks were identified and quantified along the process chain of steam reforming. A pinch analysis illustrates the requirement of additional heat flows concerning their power and temperature levels.