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Arthur D. Little in conjunction with the Department of Energy and the Illinois Department of Commerce and Community Affairs are developing an ethanol fuel processor for fuel cell vehicles. Initial studies were carried out on a 25 kWe catalytic partial oxidation (POX) reformer to determine the effect of equivalence ratio, steam to carbon ratio, and residence time on ethanol conversion. Results of the POX experiments show near equilibrium yields of hydrogen and carbon monoxide for an equivalence ratio of 3.0 with a fuel processor efficiency of 80%. The size and weight of the prototype reformer yield power densities of 1.44 l/kW and 1.74 kg/kW at an estimated cost of $20/kW.

Industrial grade ethanol, in concentrations ranging from 130 proof to 200 proof, can be used as a feedstock for a 50kWe advanced fuel processor developed by Arthur D. Little, Inc. for fuel cell vehicles. At 180 proof concentration, hydrated ethanol showed no performance degradation compared with both 200 proof (pure) ethanol and E95 (95% ethanol and 5% gasoline) at equivalence ratios ranging from 3.0 to 4.0. Environmental benefits associated with the use of ethanol in fuel cell power systems include its production from renewable biological sources, low toxicity in the event of an accidental spill, and recycling of carbon dioxide released by the process back to the plant matter used as ethanol feedstock. Cost savings associated with the use of hydrated ethanol are expected to include lower production costs, lower distribution costs, and lower powerplant costs due to the possibility of system simplification.

The feasibility of fuel cell vehicles has now been verified by virtue of recent and ongoing field experience with both hydrogen and reformer based systems. The key issues regarding the timing and extent of fuel cell commercialization are becoming the ability to reduce costs to acceptable levels and the choice of fuel for the power system. The choice of fuel processing technology can dramatically influence the total power system. The design and development of a multi-fuel reformer/fuel cell system for transportation applications has been demonstrated using both software simulations and hardware demonstrations. Feasibility has been demonstrated through six years of prototype hardware and experimental testing culminating with the reformer and CO clean-up device being integrated with a PEM fuel cell. Recent efforts have focused on improving the performance of the various subsystems and increasing the power density and specific power of the integrated fuel processing subsystem.