Superadiabatic combustion in counter-flow heat exchangers

Syngas, a combustible gaseous mixture of hydrogen, carbon monoxide, and other species, is a promising fuel for efficient energy conversion technologies. Syngas is produced by breaking down a primary fuel into a hydrogen-rich mixture in a process called fuel reforming. The motivation for the utilization of syngas rather than the primary fuel is that syngas can be used in energy conversion technologies that offer higher conversion efficiencies, e.g. gas turbines and fuel cells. One approach for syngas production is partial oxidation, which is an oxygen starved combustion process that does not require a catalyst. Efficient conversion to syngas occurs at high levels of oxygen depletion, resulting in mixtures that are not flammable in conventional combustion applications. In non-catalytic partial oxidation, internal heat recirculation is used to increase the local reaction temperatures by transferring heat from the product stream to pre-heat the fuel/air mixture before reactions occur, thus increasing reaction rates and allowing for combustion outside the conventional flammability limits. As peak temperatures lie above the adiabatic equilibrium temperature predicted by thermodynamic calculations, the combustion regime used for non-catalytic fuel reforming is referred to as 'superadiabatic'. Counter-flow heat exchange is an effective way to transfer heat between adjacent channels and is used for a novel, heat-recirculating fuel reformer design. An analytical study predicts that combustion zone locations inside adjacent flow channels adjust to operating conditions, thus stabilizing the process for independent variations of flow velocities and mixture compositions. In experiments, a reactor prototype with four channels with alternating flow directions is developed and investigated. Tests with methane/air and propane/air mixtures validate the operating principle, and measurements of the resulting syngas compositions verify the feasibility of the concept for practical fuel-reformer applications. Results from a two-dimensional numerical study with detailed reaction chemistry are consistent with experimental observations. Details of the reaction zone reveal that reactions are initiated in the vicinity of the channel walls, resulting in "tulip"-shaped reaction layers. Overall, results confirm the viability of the non-catalytic reactor design for fuel reforming applications.