Abstract: A tubular vaporizer for vaporizing volatile liquids, and especially hydrocarbon fuels. Liquid fuel is passed into the vaporizer tube, is vaporized by heat transferred through fuel contact with the hot walls, and vaporized fuel exits the vaporizer tube. A hot carrier air stream is passed through the vaporizer with the vaporized fuel, greatly reducing the rate of buildup of deposits on the vaporizer walls; however, fueling of the vaporizer eventually must be shut down to remove the deposits. The deposits are easily removed, and the vaporizer tube completely regenerated, by passing hot air alone through the tube for a period of time. In a preferred embodiment, two parallel-path vaporization tubes and switching means therebetween are provided for alternate use and regeneration cycles, affording a continuous flow of vaporized fuel from the apparatus. The vaporizer is especially useful in providing gaseous fuel for a catalytic hydrocarbon reformer.

Abstract: Disclosed herein are methods for operating a reformer and for operating a vehicle. In one embodiment, the method for operating the reformer comprises: introducing an oxidant and fuel to a reformer at greater than or equal to about 25,000/hr space velocity; combusting the oxidant and the fuel the reformer to produce a combustion gas, wherein the reformer comprises a reformer substrate comprising a reformer catalyst and having a thermal conductivity of greater than or equal to about 35 W/m° K; extinguishing the combustion; and introducing additional fuel and oxidant to the reformer at an air to fuel weight ratio appropriate for reforming. A method of using the reformate produced to reduce cold start emissions and/or regenerate an exhaust control device is also disclosed.

Abstract: An internal combustion engine is supplied with reformate from a hydrocarbon reformer at engine start-up and during engine warm-up. The reformate fuel mixture is fuel-lean at start-up to ensure that all the fuel is burned while the exhaust converter is thermally non-functional. Shortly after start-up, the mixture is changed to be fuel-rich, providing unburned reformate fuel in the exhaust stream. During start-up and warm-up, the output of an air pump is controllably divided between the reformer (primary air) and the engine exhaust system (secondary air). Unburned reformate from the engine and secondary air from the air pump ignite and thereby rapidly heat the converter. Gasoline or diesel fueling of the engine by fuel injection is preferably delayed until the engine and the converter both reach operating temperatures, whereupon the engine is fueled by fuel injection and further reforming is terminated.

Abstract: A fast start-up catalytic reformer for producing hydrogen-rich reformate from hydrocarbon fuel includes a reactor having an inlet for receiving a flow of fuel and a flow of air, a reforming catalyst disposed within a reforming chamber in the reactor, and an outlet for discharging the produced reformate stream. An ignition device within the reactor tube ignites a first lean mixture in combustion mode to generate exhaust gases to warm the catalyst which also warms the wall of the reactor adjacent the catalyst. The reactor then switches over to a rich fuel/air mixture during reforming mode. A jacket concentrically surrounds the reactor, defining a mixing chamber therebetween which communicates with the reforming chamber via openings in the wall of the reactor. Fuel entering the reformer in combustion mode is injected directly into the reforming chamber to provide rapid warming of the catalyst.

Abstract: A method for starting a fast light-off catalytic reformer for producing hydrogen-rich reformate fuel from hydrocarbon fuel and air, the reformer having means for receiving flows of fuel and air, a reforming catalyst for reforming the fuel and air mixture, and an ignition device. A control system selects fuel and air flow rates to form a lean fuel/air mixture and operates the ignition device to ignite the lean mixture to produce hot exhaust gases that flow over and heat the reforming catalyst for a first length of time. Fuel flow is then stopped temporarily for a second length of time, and further ignition is terminated. Fuel flow is then restarted and adjusted to provide a rich fuel/air mixture which is directed to the heated catalyst for reforming into reformate fuel. Air flow may also be adjusted in setting the lean and/or rich fuel/air mixtures.

Abstract: Disclosed herein are methods for operating a reformer and for operating a vehicle. In one embodiment, the method for operating the reformer comprises: introducing an oxidant and fuel to a reformer at greater than or equal to about 25,000/hr space velocity; combusting the oxidant and the fuel the reformer to produce a combustion gas, wherein the reformer comprises a reformer substrate comprising a reformer catalyst and having a thermal conductivity of greater than or equal to about 35 W/m° K; extinguishing the combustion; and introducing additional fuel and oxidant to the reformer at an air to fuel weight ratio appropriate for reforming. A method of using the reformate produced to reduce cold start emissions and/or regenerate an exhaust control device is also disclosed.

Abstract: A fast start-up catalytic reformer for producing hydrogen-rich reformate from hydrocarbon fuel includes a reactor having an inlet for receiving a flow of fuel and a flow of air, a reforming catalyst disposed within a reforming chamber in the reactor, and an outlet for discharging the produced reformate stream. An ignition device within the reactor tube ignites a first lean mixture in combustion mode to generate exhaust gases to warm the catalyst which also warms the wall of the reactor adjacent the catalyst. The reactor then switches over to a rich fuel/air mixture during reforming mode. A jacket concentrically surrounds the reactor, defining a mixing chamber therebetween which communicates with the reforming chamber via openings in the wall of the reactor. Fuel entering the reformer in combustion mode is injected directly into the reforming chamber to provide rapid warming of the catalyst.

Abstract: A method for starting a fast light-off catalytic reformer for producing hydrogen-rich reformate fuel from hydrocarbon fuel and air, the reformer having means for receiving flows of fuel and air, a reforming catalyst for reforming the fuel and air mixture, and an ignition device. A control system selects fuel and air flow rates to form a lean fuel/air mixture and operates the ignition device to ignite the lean mixture to produce hot exhaust gases that flow over and heat the reforming catalyst for a first length of time. Fuel flow is then stopped temporarily for a second length of time, and further ignition is terminated. Fuel flow is then restarted and adjusted to provide a rich fuel/air mixture which is directed to the heated catalyst for reforming into reformate fuel. Air flow may also be adjusted in setting the lean and/or rich fuel/air mixtures.