Thermally integrated heat exchange system for solid oxide electrolyte systems

Claim 2

A thermally integrated heat exchange system for a solid oxide based ion conducting system, comprising: a furnace enclosure structure having an interior chamber substantially enclosed by thermally insulated walls; a plurality of spaced apart solid oxide electrolyte plates disposed within said interior chamber, said plates arranged to permit fluid flow of incoming reactant gases therebetween; a heat exchanger associated with said thermally insulated walls for preheating said incoming reactant gases, said heat exchanger having an incoming gas passageway therein in fluid communication with a source of incoming gas and with said spaced apart electrolyte plates, and an exhaust gas passageway therein in fluid communication with said spaced apart electrolyte plates; a manifold disposed within said furnace enclosure for directing said incoming reactant gases to flow from said incoming gas passageway to said electrolyte plates, and for directing said exhaust gases to flow from said electrolyte plates to said exhaust gas passageway; and external thermal insulation substantially surrounding said furnace enclosure structure.

Claim 3

The thermally integrated heat exchange system in claim 1 wherein said heat exchanger is a screw culvert heat exchanger comprising a plurality of elongated culverts, each having an inner surface, an outer surface, and a length and having spiral corrugations resembling a coarse screw thread in said inner and outer surfaces extending along said length, said culverts each having a diameter which varies incrementally in size from culvert to culvert, said culverts arranged coaxially from the smallest diameter culvert to the largest diameter culvert one within the other and rotated one within the other such that said spiral corrugations on adjacent culverts are out-of-phase with each other and run up against one another and bind together in an interference fit, and wherein said incoming gas passageway and said exhaust gas passageway in said heat exchanger are helical shaped channels formed in said corrugations between adjacent culverts.

Claim 4

The thermally integrated heat exchange system in claim 1 wherein said heat exchanger is a plate fin heat exchanger comprising a generally cylindrical corrugated core having an inner corrugated surface with a plurality of inner core channels therein, an outer corrugated surface with a plurality of outer core channels therein, and having a thickness and a length, said inner and outer corrugated surfaces covered along said length by inner and outer face sheets respectively, and wherein said incoming gas passageway and said exhaust gas passageway comprise said inner core channels covered by said inner face sheet and said outer core channels covered by said outer face sheet.

Claim 5

The thermally integrated heat exchange system in claim 1 wherein said incoming gas passageway and said exhaust gas passageway are substantially thermally integrated along their length with substantial surface area available for transfer of thermal energy from an exhaust gas in said exhaust gas passageway to an incoming gas in said incoming gas passageway.

Claim 6

The thermally integrated heat exchange system in claim 1 wherein an incoming gas in said incoming gas passageway and an exhaust gas in said exhaust gas passageway flow in opposite directions through said heat exchanger.

Claim 7

A thermally integrated heat exchange system for a solid oxide fuel cell comprising: a furnace enclosure structure having an interior chamber substantially enclosed by thermally insulated walls; a plurality of spaced apart solid oxide fuel cell plates disposed within said interior chamber, said plates arranged to permit fluid flow of incoming reactant air and reactant fuel gases therebetween; a heat exchanger associated with said thermally insulated walls for preheating said incoming air destined to flow through said fuel cell plates, said heat exchanger having an incoming air passageway with an incoming air inlet in fluid communication with a source of incoming air and an incoming air outlet in fluid communication with said fuel cell plates, and an exhaust air passageway with an exhaust air inlet in fluid communication with said fuel cell plates and an exhaust air outlet; manifold means disposed within said furnace enclosure for directing said incoming air from said incoming air passageway to said fuel cell plates, and for directing exhaust air from said fuel cell plates to said exhaust air passageway; fuel preheating and reformation means thermally integrated with said interior chamber of said furnace enclosure for preheating incoming fuel gases destined to flow through said fuel cell plates and for reforming fuel gases to flow through said fuel cell plates; and thermal insulation substantially surrounding said furnace enclosure structure.

Claim 8

A thermally integrated heat exchange system for a solid oxide fuel cell comprising: a furnace enclosure structure having an interior chamber substantially enclosed by thermally insulated walls; a plurality of spaced apart solid oxide fuel cell plates disposed within said interior chamber, said plates arranged to permit fluid flow of incoming reactant air and reactant fuel gases therebetween; a heat exchanger associated with said thermally insulated walls for preheating said incoming air destined to flow through said fuel cell plates, said heat exchanger having an incoming air passageway with an incoming air inlet in fluid communication with a source of incoming air and an incoming air outlet in fluid communication with said fuel cell plates, and an exhaust air passageway with an exhaust air inlet in fluid communication with said fuel cell plates and an exhaust air outlet; manifold means disposed within said furnace enclosure for directing said incoming air from said incoming air passageway to said fuel cell plates, and for directing exhaust air from said fuel cell plates to said exhaust air passageway; fuel preheating and reformation means thermally integrated with said interior chamber of said furnace enclosure for preheating incoming fuel gases destined to flow through said fuel cell plates and for reforming fuel gases to flow through said fuel cell plates; and thermal insulation substantially surrounding said furnace enclosure structure.

Claim 9

The thermally integrated heat exchange system in claim 6 wherein said heat exchanger is a screw culvert heat exchanger comprising a plurality of elongated culverts each having an inner surface, an outer surface, and a length and having spiral corrugations resembling a screw thread in said inner and outer surfaces extending along said length, said culverts each having a diameter which varies incrementally in size from culvert to culvert, said culverts arranged coaxially from the smallest diameter culvert to the largest diameter culvert one within the other and rotated one within the other such that said spiral corrugations on adjacent culverts are out-of-phase with each other and run up against one another and bind together in an interference fit, and wherein said incoming air passageway and said exhaust air passageway are helical shaped channels formed in said corrugations between adjacent culverts.

Claim 10

The thermally integrated heat exchange system in claim 6 wherein said heat exchanger is a plate fin heat exchanger comprising a generally cylindrical corrugated core having an inner corrugated surface with a plurality of inner core channels therein, an outer corrugated surface with a plurality of outer core channels therein, and having a thickness and a length, said inner and outer corrugated surfaces covered along said length by inner and outer face sheets respectively, and wherein said incoming air passageway and said exhaust air passageway comprise said inner core channels covered by said inner face sheet and said outer core channels covered by said outer face sheet.

Claim 11

The thermally integrated solid oxide fuel cell system in claim 6 wherein said incoming air passageway and said exhaust air passageway are substantially thermally integrated along their length with substantial surface area available for transfer of thermal energy from said exhaust air in said exhaust air passageway to incoming air in said incoming air passageway.

Claim 12

The thermally integrated solid oxide fuel cell system in claim 6 wherein said incoming air and said exhaust air flow in opposite directions along said length of said heat exchanger through respective of said incoming air passageway and said exhaust air passageway.

Claim 13

The thermally integrated heat exchange system in claim 6 wherein said fuel preheating and reformation means are catalyst loaded tubes disposed within said furnace enclosure structure.

Claim 14

The thermally integrated heat exchange system in claim 11 including thermal insulation and radiation shields on said catalyst loaded tubes to effect a predetermined temperature progression through said catalyst bed.

Claim 15

The thermally integrated heat exchange system in claim 6 wherein said fuel preheating and reformation means is a steam reformer.

Claim 16

The thermally integrated heat exchange system in claim 6 including additional thermal insulation substantially surrounding said furnace enclosure.