Hydrogen Refueling System Based on Autothermal Cyclic Reforming

GE Energy and Environmental Research Corporation (GE-EER) is developing a hydrogen generation system designed for vehicle refueling. The hydrogen generation system uses a proprietary reformer to convert fuels to a hydrogen-rich gas that can be easily purified. The Autothermal Cyclic Reforming (ACR) process is a unique technology that can be applied for the production of hydrogen or syngas from many fuels, including natural gas, diesel fuel, coal, and renewable feed-stocks, such as biomass. The system also includes a Pressure Swing Adsorption (PSA) unit to purify the hydrogen, a hydrogen compressor, high-pressure storage tanks, and a dispensing unit to safely deliver the hydrogen from the storage tanks to the hydrogen vehicle. Praxair will develop the PSA unit, the hydrogen compressor and hydrogen storage tanks. HCI will develop the hydrogen dispenser. BP will analyze the refueling station logistics and safety. An optimal process configuration was selected, process flow diagrams were developed, and efficiencies were calculated. A detailed analysis was conducted to compare high-pressure and low-pressure reforming configurations. In collaboration with an ongoing DOE project, "Fuel Processing Based on ACR for Stationary PEM Fuel Cells", Contract No. DE-FC02-97EE50488, the component design of the fuel processor has been completed and the system is being fabricated. The fabrication is expected to be complete by July 2002. A detailed safety analysis including Personnel Hazard Assessment (PHA), Hazardous Operation (HAZOP) analysis, and Failure Mode and Effects Analysis (FMEA) has been performed. An economic analysis for the hydrogen refueling station is being performed. The installed capital costs for 150 kWt and 500 kWt (thermal) commercial hydrogen generators were estimated from the current cost of the prototype hydrogen generator. The cost of H2 was projected to understand the market position of ACR-based hydrogen generator.