Fuel Processors are chemical reaction systems that use fuel reformers to convert hydrocarbons into hydrogen-rich synthesis gases (syngas). While syngas can be used in a variety of applications Aspen Products Group, Inc. (APG) is developing fuel processors to generate hydrogen-rich synthesis gases usable in fuel cells. APG has developed fuel processors sized to power fuel cells rated from 2 to 5 kWe. The processors shown below convert military logistic fuels (Jet A, JP 5, JP 8, and diesel) into gases usable in solid oxide fuel cells. They are advanced thermally integrated reactors that employ desulfurization technologies to remove sulfur from liquid logistic fuels or from the gaseous product gas.

Development of effective fuel processors for military fuels presents materials, process, and hardware design challenges. Catalysts need to be highly active, sulfur tolerant, durable, and capable of reacting aromatic and other heavy hydrocarbons. Reactors need to provide good fuel vaporization and mixture with air or other vapors and gases, operate at low pressure drop, prevent non-selective reactions (coking), have good thermal conductivity and be durable and chemically compatible. Fuel processor system designs for military use are configured to be compact and light weight and operate without the need to carry additional water. Often overall efficiency is sacrificed to achieve low weight and volume. Stationary fuel cells are usually designed for high efficiency resulting in much heavier (and costlier) systems.

Within the scope of military missions, fuel processor designs can be optimized to further minimize weight and volume. The figure shows two approaches to meet mission needs. A fuel processor that removes sulfur after the reformer is more attractive for short or low power missions, while removal of sulfur from liquids before the processor is preferred when mission energy requirements are higher. The APG systems shown were designed to meet these challenges.