Dynamic fuel processor with controlled declining temperatures

A fuel processor for converting carbonaceous fuels into hydrogen rich gases for use with fuel cells and chemical processing applications, comprising:

• a set of three cylinders positioned substantially concentrically to each other to define an autothermal hydrodesulfurizing reforming reaction zone, a sulfur reaction removal zone and a water gas shift (WGS) reaction zone;
• said cylinders comprising an inner cylinder providing an autothermal hydrodesulfurizing reformer (AHR), an outer cylinder positioned outwardly of said inner cylinder, and an intermediate cylinder positioned between said inner cylinder and said outer cylinder;
• said AHR comprising a dome defining a diffuser zone, a fuel tube in communication with said diffuser zone, a fuel injector for feeding carbonaceous fuel into said fuel tube, an oxygen-containing gas injector for feeding air or another oxygen-containing gas into said fuel tube along with said fuel, a water injector for feeding and mixing steam or water with said fuel and oxygen-containing gas in said fuel tube;
• and
• an AHR catalyst positioned below said dome, said AHR catalyst comprising a dehydrogenation portion, an oxidation portion, and a hydrodesulfurizing portion.

A fuel processor for converting carbonaceous fuels into hydrogen rich gases for use with fuel cells and chemical processing applications, comprising:

• a set of vessels having substantially upright concentric annular walls, said vessels comprising an inner vessel, an outer vessel, and an intermediate vessel positioned between said inner vessel and said outer vessel;
• said inner vessel comprising an autothermal hydrodesulfurizing reformer (AHR) with an autothermal hydrodesulfurizing reforming reaction zone containing a bed of AHR catalyst, said AHR catalyst comprising a dehydrogenation portion, an oxidation portion, and a hydrodesulfurization portion, said inner vessel comprising a dome providing a diffuser zone positioned above said autothermal hydrodesulfurizing reforming reaction zone, a fuel tube in communication with said diffuser zone, and injectors for feeding a feed mixture of carbonaceous fuel, an oxidant, and water through said fuel tube into said diffuser zone, and said AHR catalyst reforming said feed mixture to form hydrogen-rich reformate gas in said autothermal hydrodesulfurizing reforming reaction zone;
• an annulus comprising an intermediate annular vaporizer and preheater zone positioned between said inner vessel and said outer vessel and communicating with said autothermal hydrodesulfurizing reforming reaction zone for receiving and cooling said reformate gas from said autothermal hydrodesulfurizing reforming reaction zone, said intermediate annular vaporizer and preheater zone containing a preheat coil for receiving sensible heat form said reformats gas to heat at least some of said oxidant;
• an annular sulfur removal zone positioned between said intermediate vessel and said outer vessel and communicating with said intermediate annular vaporizer and preheater zone for receiving said reformate gas from said intermediate annular vaporizer and preheater zone, said annular sulfur removal zone containing a bed of sulfur-removing catalyst for removing hydrogen sulfide from said reformate gas;
• a water gas shaft (WGS) reactor comprising an outer annular WGS reaction zone positioned below and communicating with said annular sulfur removing zone located between said intermediate vessel and said outer vessel, said WGS reactor containing a bed of WGS catalyst for converting carbon monoxide to carbon dioxide and hydrogen from said reformate gas after said hydrogen sulfide has been removed from said reformate gas in said sulfur removal zone, said WGS reactor comprising a boiler coil for heating at least some of sad water;
• and
• an outlet positioned below said inner vessel and said intermediate vessel and communicating with said WGS reaction zone for discharging said reformate gas after said carbon monoxide has been converted to carbon dioxide and hydrogen in said WGS reaction zone.