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Fuel Reforming

Ultrasonic Spray Nozzles for Fuel Reforming


Fuel Reforming

Fuel reforming processes use ultrasonic nozzles to atomize hydrocarbon-based fuels entering a reaction chamber or to coat catalyst membranes or filters with alumina slurries or polymers for enhanced membrane performance and electrolyte function. Uniform thin films maintain porosity while providing hydrophilic / hydrophobic function in the separation of syngas into hydrogen and CO2. Ultrasonic nozzles are ideal for spraying complex geometries such as screens or honeycombs without webbing of surfaces.

Applications include but are not limited to:

  • Ultrasonic atomization of hydrocarbon-based fuels such as methanol and diesel into a steam reformer for fast, thorough mixing of fuel and hot air/steam at low flow rates
  • Spraying catalyst slurries such as alumina suspensions onto perovskite membranes in a reforming chamber or conductive solid oxide fuel cells
  • Spraying polymer solution onto porous substrates to form electrolyte membranes for fuel cells or membranes for H2 separation from syn-gas
  • Various catalyst coatings onto open-cell filter components including aluminum screens, ceramic honeycombs or stainless steel foam, maintaining porosity without blocking micropores


Ultrasonic Nozzle Benefits:

  • Deagglomeration of particles in suspension
  • Uniform thin films
  • Controllable drop sizes
  • Ability to coat complex filter geometries uniformly, improving active catalyst surface area
  • Minimal overspray of expensive catalyst materials
  • Greater control for washcoat processes, with uniform deposition and control of coating thickness

Sono-Tek has been supplying automated coating systems used in alternative energy applications for many years, with a wealth of expertise in coating catalyst suspensions onto PEMs for fuel cell production. Sono-Tek systems have been installed for R&D and high volume manufacturing at some of the largest alternative energy technology manufacturers in the world.


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