Systems and methods for the on-board catalytic production of hydrogen from ammonia using a heat exchange catalyst unit and an electric catalyst unit operating in series

A system for on-board ammonia cracking for an internal combustion engine, comprising:

• an ammonia tank containing ammonia;
• a heat exchange catalyst unit fluidly coupled to the ammonia tank, wherein the heat exchange catalyst unit receives exhaust gas from the internal combustion engine and receives the ammonia from the ammonia tank;
• and
• an electric catalyst unit fluidly coupled in series via a single fluid path to the heat exchange catalyst unit, the electric catalyst unit including an electric heater,
• wherein the ammonia undergoes a cracking process in the heat exchange catalyst unit if the exhaust gas has reached a temperature sufficient to perform ammonia cracking,
• wherein the ammonia exits the heat exchange catalyst unit and flows to the electric catalyst unit and undergoes the cracking process in the electric catalyst unit if the exhaust gas has not reached a temperature sufficient to perform ammonia cracking, and
• wherein hydrogen resulting from the cracking process flows to the internal combustion engine.

A system for on-board ammonia cracking for an internal combustion engine, comprising:

• an ammonia tank containing ammonia;
• a heat exchange catalyst unit fluidly coupled to the ammonia tank, wherein the heat exchange catalyst unit receives exhaust gas from the internal combustion engine and receives the ammonia from the ammonia tank;
• and
• an electric catalyst unit fluidly coupled in series to the heat exchange catalyst unit via a single fluid path such that exhaust gas does not flow from the heat exchange catalyst unit to the electric catalyst unit, the electric catalyst unit powered using a vehicle power system,
• wherein the ammonia undergoes a cracking process in the heat exchange catalyst unit if the exhaust gas has reached a temperature sufficient to perform ammonia cracking, and
• if the exhaust gas has not reached a temperature sufficient to perform ammonia cracking:
• (1) the ammonia is pre-heated in the heat exchange catalyst unit,
• (2) the pre-heated ammonia exits the heat exchange catalyst unit and flows to the electric catalyst unit, and
• (3) the pre-heated ammonia undergoes the cracking process in the electric catalyst unit.