Integrated fuel processor for rapid start and operational control

In a fuel processing system of the type having a reformer breaking down a hydrocarbon fuel into an H2 containing reformate stream and first and second rectors disposed downstream of the reformer for reducing the level of carbon monoxide in the reformate stream, a method of rapidly starting the fuel processing system:

• generating a heated gas stream in a heating device;
• directing said heated gas stream through a first side of a heat exchanger;
• directing water through a second side of said heat exchanger to produce a steam stream;
• heating said first reactor with said heated gas stream at a first rate of heating;
• heating said second reactor with said steam stream at a second rate of heating;
• and
• controlling said heating device to adjust said heated gas stream, thereby controlling said first and second rates of heating.

A method for controlling a reforming fuel cell system, the method comprising the steps of:

• generating a H2-containing reformate in a reformer, said reformate having a level of carbon monoxide;
• passing said reformate through a first reactor to reduce said level of carbon monoxide in said reformate;
• reacting said reformate with oxygen in a fuel cell stack to create electrical energy and an anode effluent;
• inputting said anode effluent into a combustor to generate a exhaust stream
• adjustably inputting an oxidant into said combustor based on the temperature of said first reactor to control the temperature of said exhaust stream;
• and
• transferring heat from said exhaust stream directly to said first reactor such that the temperature of said first reactor is maintained within an operating range.