Microcomponent chemical process sheet architecture

Abstract: Microcomponent chemical process assembly wherein macroscale unit processes are performed by microscale components. The sheet architecture may be a single laminate (1) with a plurality of separate microcomponent sections (2) or the sheet architecture may be a plurality of laminates (31-36) with one or more microcomponent sections on each laminate. Each microcomponent (2) or plurality of like microcomponents (31-36) perform at least one chemical process unit operation. A first laminate having a plurality of like first microcomponents is combined with at least a second laminate having a plurality of like second microcomponents thereby combining at least two unit operations to achieve a system operation.

Description: FIELD OF THE INVENTION The present invention relates to a fuel processing unit and to a fuel processing method using a microcomponent sheet architecture wherein macroscale production is achieved with a plurality of microscale elements operating in parallel. BACKGROUND OF THE INVENTION In order to continually improve physical standards of living for greater numbers of people, it is necessary to achieve more results with fewer resources. From the industrial revolution through the present, economies of scale have resulted in very large components and systems of capital equipment and central operating facilities. Central facilities have the further disadvantage of requiring distribution systems which have their own capital costs and efficiency losses. Nevertheless, historically, central systems have exhibited cost advantages that supported their use. Smaller distributed components and systems are made having higher unit costs and used in applications where the substantial capital cost of a larger, more efficient component or system is not justified. Thus, there is a need for components and systems that can be made of a size appropriate for the desired capacity and can avoid the need for a distribution system yet achieve the efficiency of the larger scale components and systems. Components exhibiting high efficiency at small scale include microchannel heat exchangers used to remove heat from electronic components. US-A- 5,115,858, May 26, 1992, MICRO-CHANNEL WAFER COOLING CHUCK, Fitch et al. discusses a 3M micro-channel stock used to cool a wafer by passing a liquid coolant through alternate channels. A high heat transfer fluid is passed through the remaining channels to remove the heat. US-A 4,998,580, March 12, 1991, CONDENSER WITH SMALL HYDRAULIC DIAMETER FLOW PATH, Guntly et al. shows a condenser for use in air conditioning or refrigeration systems. Construction of the condenser is corrugated metal and flat strips. US-A- 5,016,707, May 21, 1991, MULTI-PASS CROSSFLOW JET IMPINGEMENT HEAT EXCHANGER, Nguyen describes a crossflow heat exchanger and a construction thereof by stacking multiple core and spacer plates. US-A-5,296,775, March 22, 1994, COOLING MICROFAN ARRANGEMENTS AND PROCESS, Cronin et al. discusses a micro electronic cooling fan in combination with ridges or fins, e.g., open channels. The art as shown in the above referenced patents teaches design of specific heat exchange equipment requiring substantial fabrication for individual pieces of heat exchange equipment. Use of this equipment for medium to large scale operations would require the fabrication of multiple heat exchangers wherein the cost increases linearly with the number of heat exchangers. Moreover, fabrication of a system is considered complicated and expensive on a microscale. Although it is presently possible to make microscale motors, for example, conventional wisdom combines microscale components in series with the result that achieving a macroscale result would require enormous effort and cost of making millions of tiny systems. Thus, there is a need for a heat exchanger, as well as other system components, and a fabrication technique that permits fabrication of a necessary number of heat exchangers and other components for an application wherein the unit cost per component is sufficiently low that extension to multiple components is achieved with much less cost, and wherein combination of components to form systems for macroscale results is also achieved with low cost. It has long been a challenge to utilize methane for anything other than burning. It is known that methane can produce hydrogen (Hickman and Schmidt, "Production of Syngas by Direct Catalytic Oxidation of Methane", Science, Vol. 259, January 15, 1993) by using partial oxidation, but that has only been achieved on a small scale with laboratory methods that have yet to be scaled up to useful production quantities. Hydrogen is also produced by steam reforming which requires large capital intensive plants and equipment to be cost effective. Hence, there is still a need for an apparatus and method to produce hydrogen from methane without large capital expense. Further, extracting heat from combustion processes results in thermal inefficiency because of the necessary separation of combustion reactants and products from the medium to be heated, for example steam in a coal fired power plant. It has long been desired to reduce thermal inefficiency of combustion heat transfer. In addition to chemical conversions, chemical separations are also subject to inefficiencies that limit product yield. More specifically, product purity is related to the number of separation stages which is limited by the capital expenditure for each stage. In a process wherein conversion requires temperature control, very often temperature control is achieved by excess reactant(s) or diluent(s). Hence the temperature control problem is shifted to a downstream separation problem for separating product from unreacted reactant(s) or diluent(s) and/or recovering unreacted reactant(s). Hence there is a need for a method or apparatus permitting conversions requiring temperature control to be carried out without the need for excess reactant(s) or diluent(s). SUMMARY OF THE INVENTION The present invention provides a fuel processing unit characterized in that it comprises: a first laminate having a first microcomponent, said first laminate receiving a fuel stream and rejecting a hydrogen-containing stream, a second laminate having a second microcomponent wherein flows a fluid stream, wherein the first laminate produces or receives heat to or from the second laminate, the first and second laminates comprising microchannels, and the first and second, laminates being in close proximity to each other so as to exchange heat. In a sheet architecture for example, the laminate has a plurality of microchannels. The sheet architecture may be a single laminate with a plurality of separate microcomponent sections or the sheet architecture may be a plurality of laminates with one or more microcomponent sections on each laminate. The microcomponents include passive microcomponents, for example micro flow paths, and active components including but not limited to micropumps and microcompressors. Each microcomponent or plurality of like microcomponents perform at least one unit operation. A first laminate having a plurality of like first microcomponents is combined with at least a second laminate having a plurality of like second microcomponents thereby combining at least two unit operations to achieve a system operation. For, example, a laminate containing a plurality of microchannel evaporators is combined with an insulating laminate and a laminate containing a plurality of microchannel condensers, and connected to a compressor and expansion valve to obtain a macroscale heat pump. The present invention also provides a fuel processing method, characterised in that it comprises: receiving a fuel stream and rejecting a hydrogen-containing stream in a first microcomponent of a first laminate, flowing a fluid stream in a second microcomponent of a second laminate , and wherein the first laminate produces or receives heat to or from the second laminate, the first and second laminates comprising microchannels, and the first and second laminates being in close proximity to each other so as to exchange heat. The present invention further provides a use of the fuel processing unit of the invention for converting methane to hydrogen. The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements. BRIEF DESCRIPTION OF THE DRAWINGS FIG. is an exploded view of a portion of a microscale component laminate with laterally closed lands. FIG. 1a is an exploded view of a portion of a microscale component laminate with laterally open lands. FIG. 2a is an exploded view of a portion of a microscale component laminate with connections on header ends. FIG. 2b is an exploded view of a portion of a microscale component laminate with connections along header length. FIG. 3 is a chemical process system. FIG. 4 is an exploded view of a fuel processing unit. FIG. 5a is an isometric view of a combustor. FIG. 5b is a graph of combustion efficiency versus heat rate for a combustor. DESCRIPTION OF THE PREFERRED EMBODIMENT(S) A preferred embodiment is a fuel processing unit having microcomponent sheet or laminate architecture of individual laminates wherein the fundamental structure is a laminate or laminate portion having tens to millions of microcomponents, preferably hundreds to millions, thereby enabling a laminate to provide macroscale unit operation, for example a condenser having a capacity in the kWth range, and the laminates connected, thereby combining unit operations, to form an assembly, or system, for example a chemical reactor. FUNDAMENTAL STRUCTURE FIG. 1 shows the fundamental structure of a laminate. On a material sheet or laminate 1 , a plurality of microcomponents 2 are embedded onto the material sheet 1 . Material sheets 1 may be any solid material, but are preferably metal, ceramic, or semiconductor material. A material sheet 1 embedded with microcomponents 2 is a laminate. A laminate is also a material sheet 1 having no microcomponents or having conduits through the material sheet 1 thickness serving as a spacer or insulator. The microcomponents 2 can be condensers, evaporators or non-phase change heat exchangers, compressors, expansion valves, or motors. It is to be understood that while the drawings and discussion thereof are limited to specific embodiments, there is practically no limit to the types and numbers of microcomponents and combinations thereof that may be included on a laminate or material sheet 1 . Although FIG. 1 depicts microcomponents 2 on one side of the material sheet 1 , microcomponents may be embedded on both sides of the material sheet 1. Embedding on both sides may be particularly advantageous for dual fluid heat exchangers, for example feedwater preheating with condensed turbine exhaust. The density of microcomponents 2 on a material sheet may range from about 1 microcomponent per square centimeter to about 10 10 microcomponents per square centimeter. Within those density ranges, a range of unit lengths or unit diameters of microcomponents 2 is from about 1 micron to about 1 centimeter. The width W of the grooves or microchannels 3 may range from about 1 micron to about 1 millimeter and preferably range from about 10 microns to about 250 microns. The microchannels or flow paths may be laterally closed as shown in FIG. 1, or laterally open as shown in FIG 1a. In FIGS. 2a and 2b, the microcomponents 2 are groove sets 4 made up of a pair of headers 5 and laterals 6 . Laterals 6 are the grooves permitting flow between header pairs 5 . Laterals 6 are shown substantially perpendicular to headers 5 , but is will be apparent to one skilled in the art of microcomponents that a lateral 6 can form an angle other than 90 degrees with a header 5 . Headers 5 , may be provided with connections 8 , which are enlarged portions of headers 5 , for receiving and sending fluid. The connections 8 are optional inasmuch as fluid transfer to and from the headers 5 can be accomplished within the width W of the headers 5 . Laterals 6 may have the same width as the headers 5 or have a different width either smaller or larger. It is preferred that the laterals 6 have smaller widths than the headers 5 . Embedment of microcomponents 2 or groove sets 4 may be accomplished by any microchannel forming process, but is preferably done with micromachining or photolithography. A photolithographic process is most preferred because the cost of making groove sets 4 is substantially independent of the number of groove sets 4 . Microchannel forming processes generally etch a surface so that resulting channels are unconfined on the etched side. Channels are closed by bonding a second laminate to the etched surface. The plurality of solid material lands 10 defining the laterals 6 function as heat transfer fins supporting the high heat flux observed. Each land 10 may be laterally closed as shown in FIG. 2a or laterally open as shown in FIG. 1a to permit cross flow communication. The lands 10 may be of any cross section including but not limited to rectangular, rhomboid, and ellipsoid cross sections. Laterally open lands increase flow area thereby reducing the possibility of clogging and reducing the effect of a clog should it occur. In microcomponents with laterally open lands, the definition of a lateral is less distinct especially if the lands are offset or randomly spaced. Nevertheless, the spaces between the open lands are flow paths. Although the microcomponents 3 are shown without a top cover, it is preferred that the top be closed with a cover to constrain the flow of fluid to remain within the flow paths and in intimate contact with the lands 10 . The cover may be a plain laminate having no microcomponents, for example an insulating laminate, or it may be another microcomponent laminate. SYSTEMS A single microcomponent or a set of like microcomponents is capable of performing at least one unit operation. A unit operation is defined as an operation that changes the state (thermodynamic state including chemical and/or physical state) of a working fluid including but not limited to condensation, evaporation, compression, pumping, heat exchanging, expansion, or chemical process, for example chemical conversion or separation. Chemical reactions may be endothermic or exothermic. Conversion reactions include, for example, partial oxidation and combustion. Separation involves receiving at least one chemical mixture having a chemical product and a product carrier and separating the chemical product from the product carrier. Examples of separations include distillation, ion exchange and solvent extraction. A collection of unit operations is a system. An example of a single microcomponent performing more than one unit operation is a microcompressor in a thermally conductive material performing both compression and heat transfer simultaneously. Of course macrocompressors conduct heat as a result of compressing a gas, but that heat is small compared to the process heat, for example heat removed from a refrigerated space. The distinct advantage of a microcomponent is that the heat transferred simultaneous with the compression is indeed process heat thereby providing a substantially constant temperature compression (approaching an ideal isothermal compression) which results in the most efficient energy transfer/conversion. A further example of a system is a microchannel combustor placed upon a microchannel evaporator for vaporizing a working fluid for a heat engine. Yet further, a system may comprise a microchannel chemical reactor placed upon an microchannel heat exchanger, preferably an evaporator, for temperature control of the chemical reaction thereby permitting control of partial oxidation chemical reactions. In general, a system has a first laminate having a first plurality of microcomponents for performing at least one unit operation; attached to a second laminate having a second plurality of microcomponents for performing at least one additional unit operation; wherein the unit operation is combined with the additional unit operation and produces a system operation. Alternatively, instead of having separate unit operations on separate laminates, separate unit operations may be placed on a single laminate having a first portion and at least a second portion. The first portion has first microcomponents for performing a unit operation and the second and subsequent portion(s) have second and subsequent microcomponents for performing another and subsequent unit operation(s). The unit operation is combined with the additional and/or subsequent unit operation(s) and produces a system operation. Microcomponents performing one unit operation can be combined in several ways with microcomponents performing another unit operation. For example, several microscale pumps in parallel may feed a single heat exchanger, or one microscale pump may feed several heat exchangers in parallel. Similar variations with like microcomponents in series or a combination of series and parallel arrangements may be used advantageously in particular applications. Laminates or laminate portions are combinable into a wide variety of systems including but not limited to heat pumps, heat engines, heat pipes, thermal sources, and chemical plants, for example chemical converters and chemical separators. CHEMICAL PROCESS SYSTEMS A microchannel chemical process system is one in which a chemical process unit operation is combined with at least one other unit operation. The use of microchannels for chemical processes permits greater control in the process that cannot be obtained in a conventional "macrochannel" large scale reactor. For example, a broad range of control of temperature is made possible by use of microchannel laminates. Specifically, microchannel chemical reactors used in a sheet architecture permit controlled temperature gradients or controlled temperature variation across a sheet of microchannels thereby permitting quenching and attainment of non-equilibrium states. In addition to temperature, other parameters may be closely controlled. Specifically, microchannel geometry is useful for control of residence time, or velocity profile or both. Energy other than thermal energy may be used to activate a reaction or to otherwise create an environment conducive to specific desired reactions, including but not limited to electrical on field induced reactions (e.g. plasmas or aqueous phase electrochemical reactors) magnetically induced or controlled chemical reactions and sonically induced reactions. An example of providing a temperature gradient, is having a sheet of parallel microchannels for a condenser or evaporator wherein adjacent microchannels are held at different pressures thereby experiencing phase change at different temperatures. With a reactor sheet having microchannels positioned in crossflow with respect to the condenser or evaporator microchannels, the reactions conditions are controllable along the length of the microchannel reactor. A field generator is used to induce an electric or magnetic field. The field generator is placed in proximity of the first laminate having reactor microchannels. The microchannel reactor is preferably used for reactions that do not require materials or solids that would clog the microchannels and that do not produce materials or solids that would clog the microchannels. Because the microchannel sheet architecture is capable of precise and accurate control of localized reaction conditions, for example reaction temperature and temperature gradient control at predetermined reactor location(s), it is preferred that the microchannel sheet architecture be used for reactions wherein precise control is beneficial as in partial oxidation reactions. Control of reaction temperature is critical for all partial oxidation reactions and control of residence time may be critical depending upon the reaction and reaction conditions. For example, partial oxidation of methane to hydrogen requires both control of temperature and residence time to avoid combustion of methane to carbon dioxide and water. By placing a sheet of microchannels for reaction on a sheet of microchannels for cooling, the reaction temperature is controllable to maximize yield of hydrogen. Temperature control may be achieved in any of several ways. For example when a first sheet or laminate is in a cross flow relationship to a second sheet or laminate, a temperature gradient along a flow direction of the first laminate is maintained by controlling temperature of coolant within particular microchannels or microcomponents. When two-phase flow is used in the heat transfer sheet or laminate, pressure would be used to control phase change temperature. Alternatively, geometry of the microchannels, e.g. variable flow path width, cross sectional area and/or shape may be used to optimize heat transfer to or from a chemical process sheet or laminate. Referring now to FIG. 9, a microchannel reactor 900 has a first laminate 902 reactor that receives reactants 904 , preferably fuel and oxygen, and rejects reaction products 906 . The first laminate 902 contains microchannels 908 . It is preferred that the microchannels 908 contain a coating 910 on a surface of the microchannels 908 . The coating is preferably a catalyst, or a catalyst support with catalyst or multiple catalysts. Alternatively, the coating is a permeate or a material that influences wetability or contact angle, coating materials include but are not limited to catalytic metals, for example nickel, platinum, and rhodium. Alternatively, for chemical separations, the coating 910 is a membrane or adsorbent. A second laminate 912 has microchannels 914 for receiving a liquid 916 , preferably water, and rejecting evaporate 918 , preferably steam. The phase change from liquid to evaporate is used to control the temperature of reaction in the reaction microchannels 908 . For reactions like partial oxidation wherein it is desired to control the reaction temperature, it is preferred that the cooling medium microchannels 912 be in close proximity with reaction microchannels 902 . Cooling medium microchannels 912 and reaction microchannels 902 may be in direct contact, or may have a gap therebetween. The gap may be open or filled with an insulating material. For maximum heat transfer, flow of cooling medium with respect to reactants is preferably counterflow, but may be parallel or crossflow. The evaporate may be used as a working fluid in a heat engine, for example a Rankine cycle. In an alternative embodiment, the reaction may be combustion wherein control of the temperature of combustion is not critical, rather than partial oxidation, and the phase change used solely as a working fluid in a heat engine for producing work. Additionally, a single phase fluid may be used for removing heat wherein no phase change occurs. FUEL PROCESSING UNIT For a power generation system, a fuel supply is necessary. In the case of a fuel cell, utilizing catalysts, the catalysts may be poisoned by carbon monoxide or other contaminants. Accordingly, a fuel processing unit may incorporate partial oxidation reactors, shift reactors (convert CO and H 2 O to additional H 2 and CO 2 ), a sulfur scrubber, a preferential oxidation reactor for removing remaining CO or a combination thereof. A fuel processing unit incorporating each of these features is shown in FIG. 15. EXAMPLE 4 An experiment was conducted to demonstrate a combustion reactor using microchannel components as shown in FIG. 16a. Fuel and oxidizer enter a ceramic tube 1600 . Ignition is accomplished with an electronic igniter (not shown). Combustion products pass through a header 1602 into gas flow laminates 1604. Water is passed through water flow laminates 1606 . The microchannels within the laminates 1604 , 1606 were made with electro-discharge machining in stainless steel. Grooves were nominally 300 micrometers wide by 500 micrometers deep and 34 millimeters long. The area for heat transfer was 9.98 cm 2 . In this experiment, the fuel was methane and the oxidizer was oxygen. A mass flow ratio of precisely two moles of oxygen per mole of methane was maintained so that stoichiometric combustion occurred. Water flow rate was between about 1.28 g/s (1.6 gal/hr) and 1.32 g/s. Results, in the form of combustion efficiency are shown in FIG. 16b. At low heat rates, the combustor efficiency is about 92 % based upon the higher heating value (HHV) of the fuel. At heat rates above 15 W/cm 2 , the combustion efficiency about 93% based upon the lower heating value (LHV) of the fuel or 85% based upon HHV. CLOSURE The fundamental structures and laminates are assembleable in numerous combinations of micro and macro components and corresponding unit operations, and permutations of microcomponents beyond those shown in the figures and discussed specifically herein.

Claims: Fuel processing unit (900) characterized in that it comprises: a first laminate (902) having a first microcomponent (908), said first laminate receiving a fuel stream (904) and rejecting a hydrogen-containing stream (906), a second laminate (912) having a second microcomponent (914) wherein flows a fluid stream (916), wherein the first laminate (902) produces or receives heat to or from the second laminate (912), the first (902) and second (912) laminates comprising microchannels (908 and 914), and the first (902) and second (912), laminates being enclose proximity to each other so as to exchange heat. Fuel processing unit according to claim 1, characterized in that it comprises a laminate having a microcomponent that heats an oxygen-containing stream. Fuel processing unit according to any of the preceding claims, characterized in that it comprises a laminate having a microcomponent that heats a water-containing stream. Fuel processing unit according to any of the preceding claims, characterized in that each of the laminates has a single microcomponent. Fuel processing unit according to any of claims 1 to 4, characterized in that the first laminate (902) rejects heat. Fuel processing unit according to any of claims 1 to 4, characterized in that the first laminate (902) absorbs heat. Fuel processing unit according to any of the preceding claims, characterized in that the microcomponents (908, 914) are embedded in the respective laminate (902, 912) Fuel processing unit according to any of the preceding claims, characterized in that the laminates are stacked on one another. Fuel processing unit according to claim 1, characterized in that it comprises at least one of the following microcomponents: a partial oxidation reactor (1501), a shift reactor (1502), and a preferential oxidation reactor (1503). Fuel processing unit according to any of the preceding claims, characterized in that the first microcomponent is a partial oxidation reactor (1501), and the fuel processing unit comprises at least one other laminate having a microcomponent which is a shift reactor (1502) or a preferential oxidation reactor (1503). Fuel processing method, characterized in that it comprises: receiving a fuel stream (916) and rejecting a hydrogen-containing stream (906) in a first microcomponent (908) of a first laminate (902), flowing a fluid stream (916) in a second microcomponent (914) of a second laminate (912), and wherein the first laminate (902) produces or receives heat to or from the second laminate(912), the first and second laminates (902, 912) comprising microchannels, and the first and second laminates (902, 912) being in close proximity to each other so as to exchange heat. Fuel processing method according to claim 11, characterized in that the fuel is methane. Fuel processing method according to any of claims 11 and 12, characterized in that the processing includes partial oxidation. Fuel processing method according to any of the preceding claims, characterized in that the processing reaction is exothermic. Fuel processing method according to any of the preceding claims, characterized in that the processing reaction is endothermic. Fuel processing method according to any of the preceding claims, characterized in that the fluid stream (916) is an oxygen-containing stream. Fuel processing method according to any of the preceding claims, characterized in that the fluid stream (916) is a water-containing stream. Fuel processing method according to claim 11, characterized in that the fuel stream is converted in at least one of the following steps: a partial oxidation step (1501), a shift reaction step (1502), and a preferential oxidation step (1503). Fuel processing method according to any of the preceding claims, characterized in that the fuel stream (916) is converted in a partial oxidation step (1501), and is further converted in at least one of a shift reaction step (1502) and a preferential oxidation (1503). Fuel processing method according to any of the preceding claims, characterized in that the fuel stream (904) is converted in a preferential oxidation reactor (1503) and the fuel stream (904) or the converted stream (906) exchanges heat with a water-containing stream (916). Fuel processing method according to claim 20, characterized in that the water-containing stream (916) flows through a shift reactor. Fuel processing method according to any of the preceding claims, characterized in that the fuel stream (904) is converted in a shift reaction reactor (1502) and the fuel stream (904) or the converted stream (906) exchanges heat with at least one of an oxygen-containing stream and a water-containing stream (916). Fuel processing method according to any of claims 11 to 21, characterized in that the fuel stream (904) is converted in a partial oxidation reactor (1501) and the fuel stream (904) or the converted stream (906) exchanges heat with an oxygen containing stream (916). Fuel processing method according to claim 23, characterized in that the oxygen-containing stream (916) flows through the partial oxidation reactor (501). Use of the fuel processing unit according to any of claims 1 to 10 for converting methane into hydrogen.

Inventors: BIRMINGHAM JOSEPH G, CALL CHARLES J, DROST KEVIN M, FRIEDRICH MICHELLE, KURATH DEAN E, MCDONALD CAROLYN EVANS, WEGENG ROBERT S, BIRMINGHAM, JOSEPH G., CALL, CHARLES J., DROST, KEVIN M., FRIEDRICH, MICHELLE, KURATH, DEAN E., MCDONALD, CAROLYN EVANS, WEGENG, ROBERT S.
Applicants: BATTELLE MEMORIAL INSTITUTE
Application year: 1996
Main classification: F28D9
IPC codes: C01B3, F28D9, B01B1, B01J19, F02G1