This Small Business Innovation Research (SBIR) Phase I Project will investigate the merits and feasibility of an Adaptive Compact Fuel Reformer (ACFR) using an Ultra-Fine Homogeneous Atomizer based on an autothermal process. Diesel reformer is the key to provide syngas (H2+CO) for fuel cell auxiliary power unit (APU) which can significantly reduce engine idling fuel cost. Hydrogen rich syngas with EGR is effective for simultaneously reducing engine NOx and PM emissions. However, most diesel reformers face challenges of auto-ignition control, coking and fuel slip, size and weight reduction, and durability issues, etc. The key innovation of the adaptive compact fuel reformer is an ultra-fine atomizer, which has an innovative micro-circular orifice coupling ultra-thin layer of fuel spray, steam and air flow simultaneously. The atomizer can produce very small fuel droplets (~10 micron) and homogenous mixture, which can be quickly vaporized and converted into syngas in a small space without auto-ignition, coking and slip. The Phase I work will complete the key design work for the fuel reformer and conduct lab bench scale testing for key components. The broader/commercial impacts of this research are significant potential benefits for US energy security and environment protection. The potential customers include engine OEMs and auto makers. The industry-university collaborated research will help graduate students carry on fundamental research while providing deeper understanding of diesel fuel reformation for commercial applications.
SUMMARY This Small Business Innovation Research (SBIR) Phase I Project investigates the merits and feasibility of an Adaptive Compact Fuel Reformer (ACFR) using an Ultra-Fine Homogeneous Atomizer based on an autothermal process. The key innovation of the adaptive compact fuel reformer is an ultra-fine atomizer, which has an innovative micro-circular orifice coupling ultra-thin layer of fuel spray, steam and air flow simultaneously. Innovative design was conducted to develop a unique ultra-fine atomizer along with an effective swirl adapter to enable homogenous mixture formation within the reformer. State of the art laser diagnostics instruments were used to characterize spray distributions and mixture formation of the ultra-fine atomizer. KIVA simulations were conducted to identify the merits of syngas enhanced combustion. Preliminary metal engine testing was also carried out. The results have shown that: (i) The ultra-fine homogenous atomizer (UFHA) provide more uniform spray distribution which is favorable for mixture formation for fuel reformer to reduce wall wetting, thus to reduce potential coking. (ii)Port supplied syngas charge, when combined with advanced in-cylinder direct fuel injection strategies, significantly reduces diesel engine emissions, especially reduce PM and NOx formation, while maintaining and at some cases improving fuel economy by over 10%. The Phase I results provide adequate merits to support further prototyping and engine combustion testing in phase II. The broader/commercial impacts of this research are significant potential benefits for energy security and environment protection. The potential customers include engine OEMs and auto makers. This research also contributes to fundamental understandings of syngas/hydrogen enhanced high efficiency clean low temperature combustion in general. The industry-university collaborated engineering research helps graduate students conduct fundamental research while providing deeper understanding on diesel fuel reforming for commercial applications.
