Primary reactor liquid water and air injection for improved management of a fuel processor

A method of operating a primary reactor in a fuel processing system to produce a hydrogen containing reformate from a hydrocarbon fuel, the method comprising the steps of:

• supplying a first stream having a superheated steam to an inlet of the primary reactor;
• injecting a second stream having liquid water into said first stream, during a predetermined operating condition, to vaporize at least a majority of the liquid water in a liquid water/superheated steam mixture prior to the mixture reaching the primary reactor inlet;
• adding a third stream having a preheated fuel to the primary reactor inlet, for dissociation in the primary reactor;
• introducing a fourth stream having pressurized air to the primary reactor inlet;
• measuring an inlet temperature of the primary reactor;
• and
• controlling a net flow to the primary reactor, said net flow being a combination of the first, second, third and fourth streams to the primary reactor, based on the measured inlet temperature of the primary reactor.

A method of operating a primary reactor in a fuel processing system over a semi-continuous time period to produce a hydrogen-containing reformate from a hydrocarbon fuel, the method comprising the steps of:

• supplying a first stream having a superheated steam to an inlet of the primary reactor;
• injecting a second stream having liquid water into said first stream;
• adding a third stream having a preheated fuel to the primary reactor inlet, for dissociation in the primary reactor;
• introducing a fourth stream having pressurized air to the primary reactor inlet;
• determining at least one threshold of liquid water volumetric flow above which an increased reaction heat of the primary reactor is required;
• and
• controlling a flow rate of the pressurized air to provide the increased reaction heat of the primary reactor.

A fuel processing system for reforming a hydrocarbon fuel comprising

• a primary reactor having a reactor inlet and a reactor outlet;
• a superheater including a first portion having a first inlet, a second inlet, and a first outlet in fluid communication with said inlet of said primary reactor, and a second portion having a third inlet in fluid communication with said reactor outlet;
• a source of pressurized air in fluid communication with said second inlet;
• said superheater generating a superheated steam and air stream at the first outlet;
• and
• a water supply system including a source of water in fluid communication with said first inlet, an injector in fluid communication with said first outlet, and a controller coupled to said injector for selectively injecting water into said superheated steam and air stream based on an operating state of said primary reactor.