Abstract:
A burner nozzle assembly includes: a nozzle plate having an anode off-gas (AOG) nozzle at the center of the nozzle plate and a plurality of oxidation fuel nozzles surrounding the AOG nozzle; and a channel unit coupling the AOG nozzle with an AOG introducer to allow an AOG to flow therebetween and coupling the oxidation fuel nozzles with an oxidation fuel introducer to allow an oxidation fuel to flow therebetween.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/342,353, filed on Apr. 12, 2010, in the United States Patent and Trademark Office, the entire content of which is incorporated herein by reference. 
    
    
     BACKGROUND 
     1. Field 
     The following description relates to a burner nozzle assembly that can efficiently jet anode-off gas containing oxidation fuel and hydrogen to an oxidizer, and a fuel reformer having the same. 
     2. Description of Related Art 
     A steam reforming type reformer can be used to acquire high-concentration hydrogen from a fuel cell. A heat source is required because an endothermic reaction occurs in the steam reforming type reformer. Here, a flame type burner or a catalyst type burner may be used as the heat source. 
     In the flame type burner that is generally used for a home reformer structure, it is desirable to use a burner that can stably generate heat without extinguishing the flame. 
     Further, in the catalyst type burner, it is desirable to use a burner which does not cause or develop a hot spot in the catalyst and which does not backfire, that is, a burner which does not cause a flashback in a catalytic reaction starter. In particular, in a structure reusing anode-off gas (AOG) to improve the efficiency of a fuel cell, the structure for preventing or protecting from backfire is very important because the reactivity of the hydrogen contained in a large amount in the AOG gas is very high. 
     SUMMARY 
     Aspects of embodiments of the present invention are directed toward a member that improves efficiency and operational safety of a fuel reformer, by reusing highly-reactive hydrogen by burning anode-off gas. 
     Further, aspects of embodiments of the present invention are directed toward a burner that can efficiently mix and jet main fuel and anode-off gas. 
     Further, aspects of embodiments of the present invention are directed toward a member that can supply fuel mixture without generating backfire in a structure recycling AOG to the burner of a fuel reformer in order to increase efficiency of a fuel cell system. 
     In an embodiment of the present invention, a burner nozzle assembly includes: a nozzle plate having an anode off-gas (AOG) nozzle at the center of the nozzle plate and a plurality of oxidation fuel nozzles surrounding the AOG nozzle; and a channel unit coupling the AOG nozzle with an AOG introducer to allow an AOG to flow therebetween and coupling the oxidation fuel nozzles with an oxidation fuel introducer to allow an oxidation fuel to flow therebetween. 
     The sum of the discharge areas of the oxidation fuel nozzles may be one to three and a half times the discharge area of the AOG nozzle. 
     The AOG nozzle may have a diameter not greater than 2.5 mm, and each of the oxidation fuel nozzles may have a diameter not greater than 1.5 mm. 
     The channel unit may include: an AOG channel coupling the AOG nozzle with the AOG introducer to allow the AOG to flow therebetween; and an oxidation fuel channel separated from the AOG channel and coupling the oxidation fuel nozzles with the oxidation fuel introducer to allow the oxidation fuel to flow therebetween. 
     The oxidation fuel channel may include: a first portion having a circumferentially continuous annular channel configured to receive oxidation fuel from the oxidation fuel introducer; and a second portion having a plurality of discontinuous spaces configured to distribute the oxidation fuel to the oxidation fuel nozzles. 
     In another embodiment of the present invention, a reformer includes: a reforming unit; an oxidizing unit surrounding the reforming unit; and a burner nozzle assembly configured to mix an anode off-gas (AOG) with an oxidation fuel and to supply the mixed AOG and oxidation fuel to the oxidation unit, the burner nozzle assembly including a nozzle plate having an AOG nozzle at the center of the nozzle plate to supply the AOG to the oxidation unit and a plurality of oxidation fuel nozzles surrounding the AOG nozzle to supply the oxidation fuel to the oxidation unit. 
     The burner nozzle assembly may further include a channel unit coupling the AOG nozzle with an AOG introducer to allow the AOG to flow therebetween and coupling the oxidation fuel nozzles with an oxidation fuel introducer to allow the oxidation fuel to flow therebetween. 
     The reforming unit may include: a first part; a second part; and a reforming-reacting portion between the first part and the second part and configured to convert a main fuel into a reformate, the second part surrounding the first part and having a closed end portion facing the burner nozzle assembly, the first part having an open end portion facing the closed end portion of the second part and being configured to discharge the reformate. 
     The oxidizing unit may include: an oxidizing unit body surrounding the second part of the reforming unit; and an oxidizing portion between the second part of the reforming unit and the oxidizing unit body. 
     The oxidizing portion may include an oxidizing catalyst. 
     The reformer nozzle plate of the burner nozzle assembly may be separated from the closed end portion of the reforming unit by a gap therebetween and may seal an end of the oxidizing unit. 
     The oxidizing unit may include: a mixed fuel plate facing the nozzle plate of the burner nozzle assembly and having a plurality of mixed fuel nozzles surrounding the center of the mixed fuel plate, the mixed fuel nozzles being separated from the nozzle plate of the burner nozzle assembly by a gap therebetween. 
     The mixed fuel nozzles may be further away from the central axis of the reformer than the oxidation fuel nozzles are away from the central axis of the reformer. 
     The oxidizing unit may have a first end portion facing the burner nozzle assembly, the first end portion being angled toward the central axis of the reformer; and the reforming unit may have a second end portion facing the burner nozzle assembly, the second end portion being angled away from the central axis of the reformer, wherein the mixed fuel nozzles may be between the first end portion and the second end portion. 
     The first end portion and the second end portion may define a first cross sectional annular area distal to the mixed fuel nozzles and a second cross sectional annular area proximal to the mixed fuel nozzles, and the first area may be larger than the second area. 
     The first end portion and the second end portion may further define a third area between the first area and the second area, the third area may be larger than the second area, and the first area may be larger than the third area. 
     The sum of the discharge areas of the mixed fuel nozzles may be one to four times the sum of the discharge areas of the oxidation fuel nozzles and the discharge area of the AOG nozzle. 
     The reformer may further include an evaporator configured to apply heat of exhaust discharged from the oxidizing unit to convert water into steam and to supply the steam into the reforming unit. 
     The sum of the discharge areas of the oxidation fuel nozzles may be one to three and a half times the discharge area of the AOG nozzle. 
     The AOG nozzle may have a diameter not greater than 2.5 mm, and each of the oxidation fuel nozzles may have a diameter not greater than 1.5 mm. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee. 
       The accompanying drawings, together with the specification, illustrate exemplary embodiments of the present invention, and, together with the description, serve to explain the principles of the present invention. 
         FIG. 1  is a perspective view showing a burner nozzle device according to an embodiment of the present invention; 
         FIG. 2A  is a perspective view cut along line II-II′ of  FIG. 1 ; 
         FIG. 2B  is a perspective view cut along line III-III′ of  FIG. 2A ; 
         FIG. 2C  is a perspective view cut along line IV-IV′ of  FIG. 2A ; 
         FIG. 3  is a cross-sectional view showing a burner nozzle according to an embodiment of the present invention; 
         FIG. 4  is a schematic cross-sectional view showing a fuel converter according to an embodiment of the present invention; 
         FIG. 5  is a schematic cross-sectional view showing a fuel converter according to another embodiment of the present invention; 
         FIG. 6  is a perspective view of a bottom surface of the body of an oxidizing unit; 
         FIG. 7  is a schematic cross-sectional view showing a fuel converter according to another embodiment of the present invention; 
         FIG. 8  is a schematic cross-sectional view showing an embodiment of the present invention in which an evaporator is included in a fuel converter; and 
         FIGS. 9A and 9B  are thermal distribution diagrams comparing the distribution of thermal energy on a nozzle plate according to a comparable nozzle plate ( FIG. 9A ) and an embodiment of the present invention ( FIG. 9B ). 
     
    
    
     DETAILED DESCRIPTION 
     Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings. The terms representing directions such as “up, down, left, right” used herein are considered to be based on the relationships shown in the drawings, if not specifically defined or stated. Further, the same reference numerals represent the same parts throughout the embodiments. 
     Typical fuel cells include: a fuel converter (reformer and reactor) for reforming and supplying fuel; and a fuel cell module. The fuel cell module includes a fuel cell stack for converting chemical energy into electrical energy and thermal energy in an electrochemical reaction. 
     Embodiments of the present invention relate to an oxidizing unit for supplying heat to a reformer and a burner nozzle assembly for supplying oxidation fuel to the oxidizing unit. Hereafter, embodiments of the present invention are described in more detail. 
     EXAMPLE 1 
     A burner nozzle assembly  100  is first described with reference to  FIGS. 1 to 3 . The burner nozzle assembly  100  can be divided into a nozzle plate  110 , a channel unit  120 , an oxidation fuel introducer  130 , and an AOG introducer  140 . 
     The oxidation fuel introducer  130  and the AOG introducer  140  are pipes through which fuel is supplied to an oxidizing unit  200  (see  FIG. 4 ). The oxidation fuel is supplied to the burner nozzle assembly  100  through the oxidation fuel introducer  130 , and the AOG generated in the operation of the fuel cell is supplied to the burner nozzle assembly  100  through the AOG introducer  140 . 
     The nozzle plate  110  is formed as a circular plate or may be a plate having another suitable shape (or predetermined shape). The nozzle plate  110  may be made of a heat resistant material that can endure high temperatures of about 1000° C. The AOG nozzle  111  and the oxidation fuel nozzles  112  are bored through the nozzle plate  110 . The AOG nozzle  111  is formed at the center of the nozzle plate  110 , and the oxidation fuel nozzles  112  are disposed radially at a distance (e.g., a predetermined distance) from the center of the AOG nozzle  111 . Further, the AOG and the oxidation fuel are supplied into the oxidizing unit  200  through the AOG nozzle  111  and the oxidation fuel nozzles  112 , respectively. 
     The channel unit  120  is described with reference to  FIGS. 2A to 3 .  FIG. 2B  is a transverse cross-sectional view taken along line III-III′  FIG. 2A , and  FIG. 2C  is a transverse cross-sectional view taken along line IV-IV′ in  FIG. 2A . The channel unit  120  is formed by inserting a pipe from the oxidation fuel introducer  130  and the AOG introducer  140  to the AOG nozzle  111  and the oxidation fuel nozzles  112  formed in the nozzle plate  110 , or the channel unit  120  has connecting channels therein. As shown in  FIG. 3 , the AOG is delivered from the AOG introducer  140  to the AOG nozzle  111  through an AOG channel  121 . The oxidation fuel is distributed and delivered to each of the oxidation fuel nozzles  112  from the oxidation fuel introducer  130  through oxidation fuel channels  122 . In addition, the oxidation fuel channel  122 , as shown in  FIGS. 2B and 2C , may have different upper and lower structures. That is, the lower portion  122   b  of the oxidation fuel channel may have a space that can provide a circumferentially continuous channel to receive oxidation fuel and deliver it under each of the oxidation fuel nozzles  112 , and the upper portion  122   a  of the oxidation fuel channel may have a plurality of discontinuous spaces to distribute and deliver the oxidation fuel from the lower portion  122   b  of the oxidation fuel channel to each of the oxidation fuel nozzles  112 . However, in one embodiment of the present invention, because the configuration and position of the AOG nozzle  111  and the oxidation fuel nozzles  112  on the nozzle plate  110  are important to the design of the burner nozzle assembly  100 , in the same operational range it is possible to suitably modify the configuration of the oxidation fuel introducer  130 , the configuration of the AOG introducer  140 , the configuration of the channel unit  122 , and the connection relationships of (or between) them. 
     The oxidizing unit  200  and the reformer  300  are described with reference to  FIG. 4 . For the sake of convenience, the configuration of an igniter is not shown. 
     A reformer  300  is provided for acquiring (or providing) hydrogen, which is produced from hydrocarbon-based fuel (hereafter referred to as “main fuel”) and is directly used to produce electricity in a fuel cell. In a steam reforming type reformer (which is one type of a plurality of types of reformers), although it is possible to increase the output of the cell and to produce high-concentration hydrogen, the endothermic reaction requires heat from an outside source, which is supplied by the oxidizing unit  200 . 
     The reformer  300  is formed of a double hollow container. A second part (e.g., an outer pipe)  302 , the outermost part of the reformer, is closed at its lower end by a reformer lower plate (or closed end portion)  303  facing the reformer lower plate  110 , and a first part (e.g., an inner pipe)  301  has an open lower end facing the closed end portion  303 . The main fuel undergoes a steam reforming reaction while flowing down through a reforming-reacting portion  310  disposed between the first part  301  and the second part  302 , and then is delivered upward through the first part  301 , which is configured to discharge the reformate. 
     The oxidizing unit  200  of this embodiment has a hollow cylindrical shape, and its lower end is closed by the nozzle plate  110 . The reformer  300  is disposed inside the oxidizing unit  200 . In this configuration, the reformer lower plate  303  maintains a distance (e.g., a predetermined distance) from the nozzle plate  110  and the second part  302  also maintains a distance (e.g., a predetermined distance) from the oxidizing unit body  201 . The AOG and the oxidation fuel discharged from the AOG nozzle  111  and the oxidation fuel nozzles  112  flow through the space defined between the reformer  300  and the oxidizing unit body  201 . 
     The AOG and the oxidation fuel are mixed and flow upward along the space between the second part  302  and the oxidizing unit body  201  after passing under the reformer lower plate  303 , and then oxidizes and generates heat in the oxidizing portion  210  between the second part  302  and the oxidizing unit body  201 . At least any one of PdAl 2 O 3 , NiO, CuO, CeO 2 , Al 2 O 3 , Rh, Pd, and Pt and equivalents and combinations thereof can be used as a catalyst in the oxidizing portion  210 . For the sake of convenience, the configuration of the upper portions of the oxidizing unit  200  and the reformer  300  is not shown. 
     The flow and mixing process of the AOG and the oxidation fuel are described with reference to  FIG. 4 . Here, in one embodiment, LPG, a hydrocarbon-based fuel, can be used the oxidation fuel, and air can be used as the oxidizer. On the other hand, the AOG, as described above, contains a large amount of hydrogen that is discharged without reacting with the fuel electrode of the fuel cell. Since the hydrogen is very highly reactive, backfire is likely to be generated when the AOG is directly supplied into the oxidizing unit. Therefore, it is possible to reduce the probability of backfire by mixing the AOG containing a large amount of highly-reactive hydrogen with oxidation fuel having relatively low reactivity (e.g. gas mixture of LPG and air) and supplying the mixture into the oxidizing unit. 
     In addition, because the hydrogen is very small in molecular weight, its diffusion speed is very high. Therefore, the AOG has a higher diffusion speed than the oxidation fuel when the AOG and the oxidation fuel are supplied under the same pressure. Accordingly, as shown in  FIG. 4 , the AOG is mixed with the oxidation fuel discharged from the oxidation fuel nozzles  112  and then flows into the oxidizing portion  210  after being supplied from the AOG nozzle  111  into the oxidizing unit  200 . In this operation, as described above, the hydrogen-rich AOG gas has a high diffusion speed, such that when the AOG gas is injected into oxidation fuel having large concentration, the AOG and the oxidation fuel are sufficiently mixed before reaching the oxidizing portion  210 . As a result, the mole fraction of the hydrogen in the mixture of the AOG and the oxidation fuel is reduced due to the addition of the oxidation fuel and thus the probability of backfire is correspondingly reduced. 
     The mixing ratio of the AOG and the oxidation fuel can be adjusted by adjusting the diameter of the AOG nozzle  111 , and adjusting the diameter and the number of the oxidation fuel nozzles  112 , under assumption that the supply pressures of the AOG and the oxidation fuel are the same. In other words, as the diameter of the AOG nozzle  111  increases, the mixing ratio of the AOG increases, and as the diameter or the number of the oxidation fuel nozzles  112  increases, the mixing ratio of the oxidation fuel increases. However, the size of the AOG nozzle  111  cannot be made too large due to the increased possibility of backfire, whereas when the AOG nozzle  111  is made too small in size, the amount of AOG supplied becomes too small, which also causes a problem. In some embodiments, the AOG nozzle  111  has a maximum diameter of 2.5 mm, in consideration of the possibility of backfire and the amount of AOG supplied, and the oxidation fuel nozzles  112  have a maximum diameter of 1.5 mm. 
     The diameters and the number of oxidation fuel nozzles  112  can be determined in accordance with the area of the AOG nozzle  111  and the mixing ratio. In some embodiments, the oxidation fuel is supplied in a proportion of one to three and a half times the volume of the AOG. 
     For example, when the diameter of the AOG nozzle  111  is 2.5 mm and the mixing ratio of the AOG and the oxidation fuel is 1:2, then twelve oxidation fuel nozzles  112  each having a diameter of 1 mm around the AOG nozzle  111  would supply the desired mixing ratio. In this case, the discharge areas of the nozzles are:
 
 AOG  discharge area=(1.25) 2 ×π=1.5625π
 
Oxidation fuel discharge area=12×(0.5) 2 ×π=3π
 
     In addition, the oxidation fuel nozzles  112  may be disposed at a regular distance (or spacing) such that the AOG and the oxidation fuel are uniformly mixed, in order to prevent or protect from channeling in the thermal distribution in operating the oxidizing unit  200  due to disproportionate (or substantially uneven) distribution of the hydrogen. 
     EXAMPLE 2 
     Another embodiment of the present invention is described with reference to  FIGS. 5 to 7 . This embodiment relates to the lower structure of an oxidizing unit which reinforces mixing of (or further mixes) the AOG and the oxidation fuel. 
     An oxidizing unit  200   a  according to this embodiment is closed at its lower end by a nozzle plate  110  and has an oxidizing unit lower plate  203  disposed at a distance (e.g., a predetermined distance) from a nozzle plate  111  of an oxidizing unit body  201  to close the lower portion of the oxidizing unit body  201 . Therefore, a circular plate-shaped (or disk shaped) space can be defined between the oxidizing unit plate  203  and the nozzle plate  110 . Further, mixed oxidation fuel nozzles  205  are formed through the oxidizing unit lower plate  203 . The mixed oxidizing fuel nozzles  205  are disposed at a distance (e.g., a predetermined distance) from the reformer lower plate  303  and is biased toward or closer to the oxidizing unit body  201 . 
     In this structure, the diameter of the nozzle plate  110  of the burner nozzle assembly  100  is determined such that the nozzle plate  110  can be inserted in a small gap from under the oxidizing unit body  201 . A stepped portion  113  (see  FIG. 1 ) having a larger diameter than the nozzle plate  110  is formed around the nozzle plate  110  such that the nozzle plate  110  is inserted by a depth (e.g., a predetermined depth) into the oxidizing unit body  201 . In one embodiment, it is preferable to combine (or join) the nozzle plate  110  and the oxidizing unit body  201  and then seal it by welding. 
     When the nozzle plate  110  and the oxidizing unit body  201  are combined (or joined) as shown in  FIG. 5 , a space (e.g., a predetermined space) A 2  having a circular plate (or disk) shape is defined between the nozzle plate  110  and the oxidizing unit lower plate  203 . 
       FIG. 6  is a perspective view of a bottom surface of the body of an oxidizing unit. 
     As described above, the AOG and the oxidation fuel are mixed while flowing to the oxidizing portion  210  through the channel, in which the outlet of the mixing space A 2  is blocked by the oxidation fuel nozzle  205 , such that the number of collisions of the molecules in the AOG and the oxidation fuel is increased. Accordingly, the AOG and the oxidation fuel can be mixed more easily (or more thoroughly) than in Example 1. 
     The diameters of the mixed oxidation fuel nozzles  205  depend on the amount of mixed oxidation fuel supplied. That is, in one embodiment, the total area of the mixed oxidation fuel nozzles  205  is preferably one to four times the sum of the total area of the AOG nozzle and the oxidation fuel nozzles. When it is less than the total area of the AOG nozzle and the oxidation fuel nozzles, unnecessary pressure is generated in the region A 2 , and when it is more than four times that area, the effect of mixing by the nozzle is reduced. For example, when the AOG nozzle  111  has a diameter of 2.5 mm and when there are twelve oxidation fuel nozzles  112  each having a diameter of 1 mm, there can be thirty mixed oxidation fuel nozzles  205  each having a diameter of 1.5 mm. In this case, the total area of the AOG nozzle  111  and the oxidation fuel nozzles  112  is 4.5625π and the total area of the mixed oxidation fuel nozzles  205  is 16.875π, which is about four times the sum of the area of the AOG nozzle  111  and the oxidation fuel nozzles  112 . 
     On the other hand, as shown in  FIG. 7 , the AOG and the mixed fuel are first mixed by collision of supplied gases around each nozzle and then secondarily mixed while flowing to the mixed oxidation fuel nozzles  205  through the channel. 
     EXAMPLE 3 
     Another embodiment of the present invention is described with reference to  FIG. 7 . In this embodiment, the space around the mixed oxidation fuel nozzles  205  is narrowed, as compared with Example 2. 
     In this embodiment, the lower end of an oxidizing unit body  201   b  is bent inside (or angled toward the central axis of the reformer) and the lower end of a first part  301   b  is bent outside (or angled away from the central axis of the reformer); thereafter, the lower end of the oxidizing unit body  201   b  is sealed by attaching a nozzle plate  110 . The lower end of the oxidizing body  201   b  and the lower end of the first part  301   b  define a first cross sectional annular area distal to the mixed fuel nozzles and a second cross sectional annular area, smaller than the first cross sectional annular area, proximal to the mixed fuel nozzles. The lower end of the oxidizing body  201   b  and the lower end of the first part  301   b  also define a third area between the first area and the second area, the third area being larger than the second area and the first area being larger than the third area. In order to prevent unnecessary space from being defined or formed under the first part  301   b , it is possible to seal the lower end of the first part  301   b  by providing a reformer lower plate  303   b  at a height (e.g., a predetermined height). 
     According to this configuration, it is possible to make a space A 3  that gradually becomes wider from the outlet of the mixed oxidation fuel nozzle  205 . When the mixed oxidation fuel is discharged from the mixed oxidation fuel nozzle  205  and passes through the space A 3 , the gas concentration is reduced and the flow speed of the fuel mixture is relatively high, because the space is narrow around the nozzle. This feature further reduces the possibility of backfire around the mixed oxidation fuel nozzle  205 . 
     EXAMPLE 4 
     Another embodiment which includes an evaporator  400  is described with reference to  FIG. 8 . 
     The evaporator  400  is provided to evaporate water supplied to the reformer  300  using the steam reforming method, using the thermal energy of the exhaust discharged from an oxidizing unit  200   a . In this embodiment, the evaporator  400  has a structure in which a step along which water flows and a step through which the exhaust flows are alternately disposed to increase the heat exchange efficiency of the exhaust. 
     The AOG and the oxidation fuel are supplied through the AOG nozzle  111  and the oxidation fuel nozzles  112 , respectively, mixed in a space A 2  defined between the oxidizing lower plate  203  and the nozzle plate  110 , and then discharged through the mixed oxidation fuel nozzle  205 . The discharged mixed oxidation fuel is oxidized in the oxidizing portion  210  thereby generating heat, and the exhaust created after the oxidation converts the water supplied from a water supplier  402  into steam by transmitting the remaining heat to the evaporator, and the exhaust is then discharged through an exhaust outlet  404  of the evaporator  400 . The converted steam is mixed with main fuel supplied from main fuel inlet  401  through a connecting pipe  403  and then flows to a reformer  300 . 
     The main fuel and the steam are converted into a hydrogen-rich reformate by the steam reforming method and then flows through a first part  301  to a reactor for reducing carbon monoxide or the fuel electrode of the fuel cell. 
     A thermal distribution diagram on the nozzle plate  110  in the operation of the reformer having the above configuration is shown in  FIG. 9B . As shown in  FIG. 9 , the thermal balance is more uniform in thermal distribution diagram when using the configuration of the burner nozzle assembly  100  of embodiments of the present invention ( FIG. 9B ) than when using a comparable burner nozzle assemblies ( FIG. 9A ). Therefore, the AOG and the oxidation fuel appear to be more uniformly mixed by embodiments of the present invention. 
     Although preferred embodiments of the present invention were described above, the scope of the present invention is not limited to the preferred embodiments and can be implemented by a variety of nozzle assemblies and reformers having the nozzle assemblies without departing from the scope of the present invention described in claims, and equivalents thereof.