Production Of Syngas For Fuel Cells Using Multiple Catalyst Configuration

A method for supplying a product gas mixture comprising hydrogen and carbon monoxide to a solid oxide fuel cell system, said productgas mixture being produced by a conversion of hydrocarbon fuel, comprising the steps of:

• providing a feed gas mixture comprising an oxygen containing gas and a heavy hydrocarbon fuel;
• providing a catalytic structure comprising an oxidation catalyst and a steam reforming catalyst supported on an open-channel support, the steam reforming catalyst being different than the oxidation catalyst;
• passing said feed gas mixture through said catalytic structure, said catalytic structure being maintained at a temperature sufficient to produce an exit gas stream containing hydrogen and carbon monoxide as main reaction products;
• and
• directing said product gas mixture to said solid oxide fuel cell system.

A reactor for converting of hydrocarbon fuel to an exit gas stream containing hydrogen and carbon monoxide as main reaction products comprising:

• a reactor shell having an inlet and an outlet and forming a reaction flow passage extending from the inlet to the outlet, the reactor shell also forming a catalytic reaction zone between the inlet and the outlet;
• a catalytic structure disposed in the catalytic reaction zone comprising an oxidation catalyst and a steam reforming catalyst supported on an open-channel support,
• the steam reforming catalyst being different than the oxidation catalyst;
• and
• a source of hydrocarbon fuel,
• so that when a feed gas mixture comprising an oxygen containing gas and the hydrocarbon fuel is fed through the inlet, said feed gas mixture passes along the reaction flow passage and through said catalytic structure, said feed gas mixture converts in the catalytic structure to the exit gas stream containing hydrogen and carbon monoxide as main reaction products, and the exit gas stream discharges through the outlet.

A system for producing electric power comprising:

• a reactor for converting of hydrocarbon fuel to produce an exit gas stream containing hydrogen and carbon monoxide as main reaction products;
• and
• a fuel cell disposed for receiving the exit gas stream and consuming the hydrogen to produce electric power,
• the reactor comprising:
• a reactor shell having an inlet and an outlet and forming a reaction flow passage extending from the inlet to the outlet, the reactor shell also forming a catalytic reaction zone between the inlet and the outlet, a pre-reaction zone upstream of the catalytic reaction zone, and a post reaction zone downstream of the catalytic reaction zone;
• a catalytic structure disposed in the catalytic reaction zone comprising an oxidation catalyst and a steam reforming catalyst both supported on an open-channel support, the steam reforming catalyst being different than the oxidation catalyst;
• and
• a source of hydrocarbon fuel;
• so that when a feed gas mixture comprising an oxygen containing gas and the hydrocarbon fuel is fed through the inlet, said feed gas mixture passes along the reaction flow passage and through said catalytic structure, said feed gas mixture converts in the catalytic structure to the exit gas stream, and the exit gas stream discharges through the outlet.