Fuel processor primary reactor and combustor startup via electrically-heated catalyst

An auto-thermal reactor for a fuel processing system, said reactor comprising:

• a mixing region;
• a liquid fuel spray injector for spraying a liquid hydrocarbon fuel into the mixing region;
• an air/steam inlet for introducing an air/steam mixture into the mixing region, said mixing region mixing the air/steam mixture into a fuel mixture;
• a radiant shield positioned adjacent to the mixing region for protecting the mixing region from heat;
• an electrically heated catalyst positioned adjacent to the radiant shield for receiving the fuel mixture, said electrically heated catalyst being electrically heated at start-up of the fuel processing system so as to generate an exothermic reaction;
• a light-off catalyst receiving the fuel mixture from the electrically heated catalyst, said light-off catalyst also providing an exothermic catalytic reaction, wherein the electrically heated catalyst is a forward portion of the light-off catalyst;
• and
• a main catalyst receiving the fuel mixture from the light-off catalyst, said main catalyst providing a catalytic reaction for converting the fuel mixture to a hydrogen-rich gas stream, said electrically heated catalyst, light-off catalyst and main catalyst being positioned in a common housing.

A reactor for a fuel processing system, said reactor comprising:

• a fuel inlet for introducing a fuel into the reactor;
• an air/stream inlet for introducing an air/stream mixture into the reactor;
• a mixing region for mixing the air/stream mixture and the fuel into a fuel mixture;
• an electric heater receiving the fuel mixture, said electric heater including a catalyst, said electric heater being electrically heated at start-up of the fuel processing system;
• a light-off catalyst receiving the fuel mixture from the electric heater;
• a main catalyst receiving the fuel mixture from the light-off catalyst, said main catalyst converting the fuel mixture to a hydrogen-rich gas stream, said electric heater, light-off catalyst and main catalyst being positioned in a common housing;
• and
• a water inlet for introducing water into the mixing region.

A reactor for a fuel processing system, said reactor comprising:

• a fuel inlet for introducing a fuel into the reactor;
• an air/steam inlet for introducing an air/steam mixture into the reactor;
• a mixing region for mixing the air/steam mixture and the fuel into a fuel mixture;
• an electrically heated catalyst receiving the fuel mixture, said electrically heated catalyst being electrically heated at start-up of the fuel processing system;
• a light-off catalyst, said light-off catalyst receiving the fuel mixture from the electrically heated catalyst;
• a main catalyst receiving the fuel mixture from the light-off catalyst, said main catalyst converting the fuel mixture to a hydrogen-rich gas stream, said electrically heated catalyst, light-off catalyst and main catalyst being positioned in a common housing;
• and
• a water inlet for introducing water into the mixing region.

A reactor for a fuel processing system, said reactor comprising:

• a fuel inlet for introducing a fuel into the reactor;
• an air/steam inlet for introducing an air/steam mixture into the reactor;
• a mixing region for mixing the air/steam mixture and the fuel into a fuel mixture;
• an electrically heated catalyst receiving the fuel mixture, said electrically heated catalyst being electrically heated at start-up of the fuel processing system;
• a light-off catalyst, said light-off catalyst receiving the fuel mixture from the electrically heated catalyst;
• a main catalyst receiving the fuel mixture from the electrically heated light-off catalyst, said main catalyst converting the fuel mixture to a hydrogen-rich gas stream, said electrically heated catalyst, light-off catalyst and main catalyst being positioned in a common housing;
• and
• a distribution device, said distribution device receiving the air/stream mixture and distributing the air/stream mixture into the mixing region.

An auto-thermal reactor for a fuel processing system, said reactor comprising:

• a mixing region;
• a liquid fuel spray injector for spraying a liquid hydrocarbon fuel into the mixing region;
• an air/steam inlet for introducing an air/steam mixture into the mixing region, said mixing region mixing the air/steam mixture into a fuel mixture;
• a radiant shield positioned adjacent to the mixing region for protecting the mixing region from heat;
• an electrically heated catalyst positioned adjacent to the radiant shield for receiving the fuel mixture, said electrically heated catalyst being electrically heated at start-up of the fuel processing system so as to generate an exothermic reaction;
• a light-off catalyst receiving the fuel mixture from the electrically heated catalyst, said light-off catalyst also providing an exothermic catalytic reaction;
• a main catalyst receiving the fuel mixture from the light-off catalyst, said main catalyst providing a catalytic reaction for converting the fuel mixture to a hydrogen-rich gas stream, said electrically heated catalyst, light-off catalyst and main catalyst being positioned in a common housing;
• and
• a water spray injector for spraying water into the mixing region.

An auto-thermal reactor for a fuel processing system, said reactor comprising:

• a mixing region;
• a liquid fuel spray injector for spraying a liquid hydrocarbon fuel into the mixing region;
• an air/steam inlet for introducing an air/steam mixture into the mixing region, said mixing region mixing the air/steam mixture into a fuel mixture;
• a radiant shield positioned adjacent to the mixing region for protecting the mixing region from heat;
• an electrically heated catalyst positioned adjacent to the radiant shield for receiving the fuel mixture, said electrically heated catalyst being electrically heated at start-up of the fuel processing system so as to generate an exothermic reaction;
• a light-off catalyst receiving the fuel mixture from the electrically heated catalyst, said light-off catalyst also providing an exothermic catalytic reaction;
• a main catalyst receiving the fuel mixture from the light-off catalyst, said main catalyst providing a catalytic reaction for converting the fuel mixture to a hydrogen-rich gas stream, said electrically heated catalyst, light-off catalyst and main catalyst being positioned in a common housing;
• and
• a distribution device, said distribution device receiving the air/steam mixture and distributing the air/steam mixture into the mixing region.