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Investigation of an Integrated Autothermal Reforming (ATR) and SOFC Micro

Cogeneration System for Power Generation

Article · January 2006

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 WHEC 16 / 13-16 June 2006 – Lyon France

Investigation of an Integrated Autothermal Reforming (ATR) and

SOFC Micro Cogeneration System for Power Generation

Atilla ERSOZ a, Alper SARIOGLAN a

Sibel OZDOGAN b
a
TUBITAK Marmara Research Center
Institute of Energy, 41470, Gebze KOCAELI, TURKIYE
Tel. +90.262.6412300, Fax. +90.262.6412309
atilla.ersoz@mam.gov.tr
b
Marmara University, Faculty of Engineering,
Department of Chemical Engineering
Goztepe – Istanbul
sozdogan@eng.marmara.edu.tr

ABSTRACT:

In today's era of cogeneration (and trigeneration) power and energy plants with higher efficiencies and lower
costs and emissions, in the "micro" sizes are becoming more prevalent. We define the term "micro-
cogeneration" as the sizes under 1.0 MW. Cogeneration technologies are conventional power generation
systems making use of the energy remaining in exhaust gases, cooling systems, or other energy waste
stream. Typical cogeneration prime movers include, combustion turbines, reciprocating engines, boilers with
steam turbines, micro turbines and fuel cells (SOFC, MCFC and PEM). There are several methods of
producing hydrogen from fossil resources such as natural gas or naphtha, for example steam reforming,
partial oxidation and auto-thermal reforming.

KEYWORDS: Fuel cells, hydrogen, micro cogeneration, reforming

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Introduction

Fuel cell systems are being developed for supplying primary power (heat and electricity) for residential
applications of the near future. Residential power generation systems can be operated to provide primary or
backup power for the home. They can run independently or in parallel to an existing power grid. There are
several companies currently working on residential fuel cells. Several demonstration units are being tested
by the fuel cell companies around the countries in cooperation with local governments and/or utilities. The
pre-commercial units are expected to enter into the market in the 2005-2010 timeframe. Many fuel cell
manufacturers are considering the use of natural gas as a hydrogen-carrier fuel for rural and remote
residential fuel cell applications.

Fuel cells combine hydrogen and oxygen without combustion to produce electricity. Water and heat are the
only byproducts of this reaction. The process combines oxygen from the air and hydrogen extracted from
any one of a number of suitable hydrogen containing fuels. The result is DC electrical power produced with
greater efficiency than most of the other conventional power generation methods, such as internal
combustion engine generators. The net electric efficiency of low temperature fuel cell systems is
approximately 35 to 45 %. Fuel cells generate electrical power from hydrogen or a hydrogen rich gas and air
via electrochemical reactions [1–6]. There is continuous interest in converting current hydrocarbon fuels such
as natural gas, propane, gasoline and diesel into hydrogen rich gases acceptable by PEM and SOFC fuel
cells [2-10].

Commercial application of fuel cell technologies will require selection of appropriate operating conditions. By
varying operating conditions, a wide range of power and efficiency may be derived from an SOFC system.
The operating parameters may be selected based on requirements for power, efficiency, or a function of both
variables such as cost of electricity [11].

Fuel reforming systems can extract hydrogen from a variety of conventional fuel sources for the residential
micro cogeneration application with fuel cell. Existing infrastructures such as natural gas pipelines and
propane distribution systems can be used for these systems. Hydrogen rich gases can be produced via
various fuel processing technologies. Steam reforming, partial oxidation and autothermal reforming (ATR)
are the three major fuel-processing technologies [5-8].

Methodology

The use of chemical flow sheeting software has become an integral part of the evaluation of the performance
of fuel cell systems (Petterson, 2001, Kivisaari et all., 2001). In this study, the Aspen-HYSYS 3.2 simulation
software has been used to evaluate several fuel-reforming technologies for residential fuel cell micro
cogeneration systems. This paper presents the results of a study for a 5 kWe DC electrical power residential
SOFC fuel cell system utilizing several reforming technologies fed by natural gas fuel.

The process simulation code “Aspen-HYSYS 3.2” has been used for residential fuel cell system calculations.
Natural gas has been simulated as three different sources for hydrogen production. The chemical
compositions of the natural gas fuel are summarized in Table 1. The average molecular weight of natural gas
is around 16.6 kg/kmol. All simulation studies are performed based on this composition.

Table 1. Natural gas composition

Component Mass Fractions (w %) Molar fractions (mol % )

Methane 0.9693 0.9375
Ethane 0.0227 0.0412
Propane 0.0080 0.0212
Total 100 100

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The simulated residential SOFC fuel cell system consists of the following sections and their components:

ƒ Fuel processing section,

ƒ Fuel cell section,
ƒ Auxiliary units,

The overall residential fuel cell micro cogeneration system can be seen in Figure 1. The fuel processing is
one of the sections of this whole system.

Figure 1. Schematic diagram of a residential fuel cell micro cogeneration system

The aim of this study is to convert as much as the hydrogen in the fuel into hydrogen gas while decreasing
CO and CH4 formation. Process parameters of fuel preparation steps have been determined considering the
limitations set by the catalysts and hydrocarbons involved. Lower S/C ratios favor soot and coke formation,
which is not desired in catalytic steam and auto thermal reforming processes. A considerably wide S/C ratio
range has been selected to see the effect on hydrogen yield and CO formation.

The mole fractions of air have been simulated as 0.21 and 0.79 for O2 and N2 respectively. The two
parameters, S/C (steam to carbon), O/C (oxygen to carbon) ratios have been used to analyze the reforming
reactors effectively. These two relationships can be written as follows:

O/C = 0.5 * (F O2 / F CH4)

S/C = F H2O (v) / F CH4

The catalytic properties limit applicable operational parameter ranges such as S/C, O/C and operation
temperatures and pressures. The durability of the reformer is governed by the thermal durability of the
reforming catalysts by coke formation. In reality, a certain catalyst for a reforming system might be able to be
used at higher temperatures, but most commercially available catalysts have been operated at less than 800
°C to secure their thermal durability. Therefore, it is necessary to determine favorable operating conditions
for each of the reforming reactors [13].

The thermodynamic equilibrium system calculations are based on minimizing the Gibbs free energy. The
equilibrium temperature and outlet compositions of each reactor have been calculated with simulation
studies. For all cases, reactor simulation calculations have been performed under adiabatic conditions
keeping “Treactor” almost constant taking reaction heats into account. Within this frame selected S/C and/or
O/C ratio(s) are studied parametrically to achieve finally acceptable hydrogen production yield along with low
CO formation. The ranges of operating conditions investigated in the simulation studies are given in Table 2.

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Table 2. The investigated ranges of ATR reactor operating conditions

Temperature Pressure
S/C O/C
Reforming reactor (°C) (bar)
ATR 400-800 3 0.3-3 0.35-0.6

SOFC section of the overall system has been simulated in the study for all reforming process options. Fuel
cell system and the auxiliary units consist of the following components:

¾ SOFC section
ƒ SOFC stack
ƒ DC/AC converter

Table 3 summarizes the data of different auxiliary system components utilized in the simulation studies.

Table 3. Auxiliary system component data

Component Parameter Value

Water pump Adiabatic efficiency (%) 75
Cooling water pump Adiabatic efficiency (%) 75
Compressor Adiabatic efficiency (%) 75
Heat exchangers Minimum temperature approach (°C) 25
Combustor Outlet temperature (°C) 720
Chimney Outlet temperature (°C) 90
DC/AC Converter Conversion efficiency (%) 98

Fuel processing (ηFP), SOFC (ηFC) and overall system efficiencies (ηnet.el) are calculated as follows:

ηFP = η6
ηFC = (UH2) x (ηstack voltage ) x (ηDC/AC)
ηnet.el = η8 = η FP x ηFC x ηAux.

η : Efficiency

Results and Discussion

The efficiencies of three different fuel processing options and overall system efficiencies of natural gas for
the investigated fuel-reforming options are presented in Table 4. The simulation results (Table 4) indicate
that the fuel processing efficiencies decrease in the order of steam reforming > autothermal reforming >
partial oxidation for both gasoline and diesel fuels.

The promising and efficient reforming options are the steam reforming and autothermal reforming processes,
as can be seen in Table 4. We can compare these two efficient systems in order to observe the equilibrium
behavior in the reforming section of the whole micro CHP system. Here, the results of the most efficient
options, namely natural gas with steam reforming and autothermal reforming.

Table 4. Fuel processing and overall system efficiencies of natural gas fuel

Natural gas
Parameter SREF ATR POX
P, bar 3 3 3
T, °C 750 750 750
ηFP 98 93 76
ηnet.el 41 38 29

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The major units of the Aspen-HYSYS simulation for natural gas steam reforming based fuel cell system are
presented in Figure 2.

Figure 2. Schematic of Aspen-HYSYS simulation model

Autothermal reforming reactor (ATR) is maintained under adiabatic conditions. There is no heat transfer from
or to the reactor section during the reaction. The effect of S/C and O/C ratios on the net electric efficiency of
the system with fuel cell has been calculated. The results are illustrated for different inlet temperatures (700 °
and 400 °C) in Figure 3 and 4. A decrease of the S/C ratio decreases the efficiency. On the other hand, an
increase of the O/C ratio increases the efficiency in general. The operating parameters of the ATR reactor
are selected as the inlet temperature of 800°C, S/C=1.5 and O/C=0.45 within the optimum efficiency range.

45
Net electric efficiency (%)

40

O/C = 0.35
O/C = 0.40
35 O/C = 0.45
O/C = 0.50
O/C = 0.55
O/C = 0.60

30
0.3 0.5 0.8 1.0 1.3 1.5 1.8 2.0 2.3 2.5 2.8 3.0

S/C

Figure 3. S/C effect on the net electric efficiency with different O/C (T ATR inlet = 700 °C)

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40

35
Net electric efficiency (%)

30 O/C=0.35

O/C=0.40

O/C=0.45

O/C=0.50
25
O/C=0.55

O/C=0.60

20
0.0 0.5 1.0 1.5 2.0 2.5 3.0
S/C

Figure 4. S/C effect on the net electric efficiency with different O/C (T ATR inlet = 400 °C)

The evaluation of the effect for different S/C and O/C ratios on the temperature difference between the
reactor inlet and the outlet has been shown in Figure 5 and 6. The O/C ratio significantly effects the delta T
as seen in related figures. The S/C ratio also affects the temperature difference. A decrease of the S/C
increases the difference between inlet and outlet reactor temperatures. Higher S/C means lower delta T. The
most promising inlet reactor temperature is selected as 700 °C according to the catalysts thermal durability
limitations. The value of the delta T is between 50 °C and 100 °C with selected O/C=0.45. The optimum
operating value is calculated as around 60 °C (outlet temperature is around 760 °C) for S/C=1.5 and
O/C=0.45.

400

350

300

250
Delta T, °C

200

150 O/C = 0.35

O/C = 0.40
100 optimum
O/C = 0.45
50 O/C = 0.50
O/C = 0.55
0 O/C = 0.60
0.3 0.5 0.8 1.0 1.3 1.5 1.8 2.0 2.3 2.5 2.8 3.0
-50

S/C

Figure 5. S/C effect on Delta T (TATR out – T ATR in) with different O/C (T ATR inlet = 700 °C )

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450

400

350
Delta T, °C

300 O/C = 0.35

O/C = 0.40
O/C = 0.45
250
O/C = 0.50
O/C = 0.55
200
O/C = 0.60

150
0.3 0.5 0.8 1.0 1.3 1.5 1.8 2.0 2.3 2.5 2.8 3.0
S/C

Figure 6. S/C effect on Delta T (TATR out – T ATR in) with different O/C (T ATR inlet = 400 °C )

The outlet concentrations and the net electrical efficiency of the system have been similarly observed for the
different reactor inlet temperatures for the selected operating parameters (S/C=1.5 and O/C=0.45) (Figure 7
and 8). The net electric efficiency value is around 41 % for the selected inlet temperature (700 °C). The
outlet molar flow of hydrogen and carbon monoxide are 0.12 and 0.034 kmol/h. respectively. The mole
fraction of hydrogen decreases after O/C=0.45 as seen in Figure 12. The mole fraction of carbon monoxide
increases with increasing O/C ratios at selected S/C ratio of 1.5. Methane, carbon dioxide and water
concentrations are also decreasing with increasing O/C ratios.

45 0.16

40 0.14

35 0.12
Net electric efficiency, %

Flow, kmol/h.

30 0.1

25 0.08

20 0.06

O/C= 0.45, S/C=1.5

15 0.04
ATR outlet H2,kmol/h.
10 0.02
ATR outlet CO,kmol/h.

5 0
300 400 500 600 700 800

ATR inlet temperature,°C

Figure 7. ATR inlet temperature effect on the net electric efficiency with selected O/C and S/C

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0.50

0.40
Mole fraction (%)

0.30
CH4

CO
0.20
CO2

H2
0.10
H2O

0.00
0.150 0.250 0.350 0.450
O/C

Figure 8. O/C vs Comp. mol fractions at S/C=1.5 (T ATR inlet = 700 °C)

0.40

0.30
Mole fraction (%)

0.20
CH4
CO
CO2
0.10
H2
H2O

0.00
300 400 500 600 700 800
ATR İnlet Temperature (°C)

Figure 9. Effect of ATR inlet temp on ATR outlet compositions at S/C=1.5 O/C=0.45

The effect of ATR inlet temperature on the outlet reactor compositions for the selected operating conditions
(S/C=1.5 O/C=0.45) is given in Figure 9. The maximum hydrogen yield can be observed with the selected
inlet reactor temperature of 700 °C. The value is hydrogen mole fraction is 0.39 for this operating condition.

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Concluding remarks

The thermodynamic characteristics of the several reforming options namely, steam reforming, autothermal
reforming and partial oxidation have been investigated. All these reforming process options have been
investigated with appropriate simulation conditions for 5 kW fuel cell power. The most promising operating
conditions has been selected for each process. The material and energy balance calculations have also
been performed by using ASPEN-HYSYS simulation code.

Natural gas appears as the best fuel for hydrogen rich gas production due to its favorable composition from
lower molecular weight compounds. Steam reforming and autothermal reforming appear as the most
competitive fuel processing options in terms of fuel processing efficiencies. POX shows the lowest fuel
processing efficiency level. Among the options studied the highest fuel processing efficiency is achieved with
natural gas steam reforming at about 98%.

Several operating conditions have been found which satisfy the requirements for no coke formation. The
optimum S/C ratio at 3.5 appears to fulfill the requirements for temperatures around 800 °C for steam
reforming process. The optimum O/C and S/C ratios are found 0.45 and 1.5 respectively for ATR reactor
simulations at the inlet temperature of 700 °C. High system efficiency levels can be achieved only with
intensive heat integration within the fuel cell micro CHP systems. Hence, heat integration system studies are
of utmost importance along with the development of novel reforming catalysts, SOFC fuel cell components if
on-site hydrogen production is desired for micro CHP applications.

References

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Hydrocarbon Fuel Processing Option For PEM Fuel Cell. Journal of Power Sources, 118, (2003), (1-2), 384-
392.
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