For fuel cell applications, pure hydrogen generators are not a very good solution as they are bulky, heavy and expensive. Fortunately a fuel cell can run very good on a hydrogen rich stream rather then pure hydrogen. Therefore a fuel processor consisting of a reforming reactor in combination with a shift and prox are a more favorable solution. Also the low storage density of hydrogen or the lack of sufficient hydrogen infrastructure can be a driving force to choose for a more compact on-board fuel processor. Moreover on-board reforming gives a choice to use several (green) fuels, such as methanol, ethanol, biodiesel and DME. In certain stationary fuel cell applications similar needs for on-board reforming exist.

OEM’s who need to adapt their products to the new technology of fuel cells are often not well experienced in fuel cell and reforming technologies. HyGear with its extensive experience in reforming technologies and fuel cell system integration can be a partner in developing the required solutions.

Cooperation forms

Acknowledging the fact that in many cases an experienced partner offers advantages for OEM’s planning to extend their portfolio with fuel cell based solutions, Hygear offers to assist in the different phases of product development starting from feasibility studies, through basic engineering and detailed design up to prototyping and pilot series production.

In a feasibility study a technical and economical evaluation is made, based on which decisions can be made to pursue a certain fuel cell solution. HyGear’s extensive knowledge of fuel cell technologies is fully used in such a study, helping companies to get a good view on their chances for success. Especially for larger size fuel cell systems basic engineering is a logical next step in which a first system lay-out is presented basic on a first round of calculations, modeling and component selection. During basic engineering some high level choices are made giving a good first impression regarding system size, costs, etc. In detailed engineering, calculations and modeling are performed with a higher level of detail. Based on the results of this reactors (such as reformer, shift, prox) and balance of plant are designed using state of the art 3D-design software. Also all required standard components are selected and a detailed bill of material is defined. Usually HyGear then manufactures one or more prototypes. If requested this can be extended to first small series.

Forms of cooperation vary depending on the exact needs of the OEM, but usually start with using existing know how and extending this towards the required specific fuel cell based solution. Usually a technology transfer and licensing construction form part of the cooperation. Contract based development projects can cover the whole fuel range from existing fossil fuels, such as diesel or kerosene up to new synthetic biofuels such as ethanol and DME. Also in terms of size there are no limitations; micro fuel processors as well as reformers up to several hundred kilowatts are within HyGear’s scope of contract based development projects.

Basic design of fuel processor for 100 kWe PEM fuel cell system

Prototype fuel processor for 5 kWe PEM fuel cell system