Compact fuel processor for producing a hydrogen rich gas

1. A process for converting hydrocarbon fuel into a hydrogen rich gas comprising:

providing a fuel processor having a plurality of modules stacked end-to-end along a common axis wherein the plurality of modules includes:

a first module wherein a first process step occurs within the first module wherein the first process step is the partial oxidation and steam reforming of the hydrocarbon fuel to produce a first module effluent;

a second module positioned adjacent to the first module wherein a second process step occurs within the second module wherein the second process step is cooling the first module effluent to produce a second module effluent;

a third module positioned adjacent to the second module wherein a third process step occurs within the third module wherein the third process step desulfurizes the second module effluent to produce a third module effluent;

a fourth module positioned adjacent the third module wherein a fourth process step occurs within the fourth module wherein a fourth process step mixes water with with the third module effluent to produce a fourth module effluent;

a fifth module positioned adjacent to the fourth module wherein a fifth process step occurs within the fifth module wherein the fifth process step reacts the water and the carbon monoxide contained in the fourth module effluent to produce a fifth module effluent having a reduced carbon monoxide concentration;

a sixth module positioned adjacent to the fifth module wherein a sixth process process step occurs within the sixth module wherein the sixth process step is cooling the fifth module effluent to produce a sixth module effluent;

a seventh module positioned adjacent to the sixth module wherein a seventh process step occurs within the seventh module wherein the seventh process step is oxidizing at least some carbon monoxide to produce the hydrogen rich gas; and

feeding the hydrocarbon fuel successively through each of the modules in an axial direction to produce the hydrogen rich gas.

2. The process as described in claim 1 , wherein the hydrocarbon fuel is preheated by the second module, the fifth module, the sixth module, the seventh module, or any combination thereof.

3. The process as described in claims 1 , wherein the first module operates at a temperature ranging from about 550° C. to about 900° C.

4. The process as described in claim 1 , wherein the second module effluent is from about 200° C. to about 600° C.

5. The process as described in claim 1 , wherein the fifth module operates at a temperature ranging from about 150° C. to about 400° C.

6. The process as described in claim 1 , wherein the fifth module effluent is cooled to a temperature of from about 90° C. to about 150° C.

7. The process as described in claim 1 , wherein the seventh module operates at a temperature of from about 90° C. to about 150° C.

8. The process as described in claim 1 , wherein the hydrogen rich gas contains less than 50 ppm carbon monoxide.

9. A process for converting hydrocarbon fuel into a hydrogen rich gas comprising:

providing a fuel processor having a plurality of modules stacked end-to-end along a common axis wherein the plurality of modules includes:

a first module wherein a first process step occurs within the first module wherein the first process step is the partial oxidation and steam reforming of the hydrocarbon fuel to produce a first module effluent;

a second module positioned adjacent to the first module wherein a second process step occurs within the second module wherein the second process step is cooling the first module effluent to produce a second module effluent;

a third module positioned adjacent to the second module wherein a third process step occurs within the third module wherein the third process step desulfurizes the second module effluent to produce a third module effluent;

a fourth module positioned adjacent to the third module wherein a fourth process step occurs within the fourth module wherein the fourth process step reacts water and the carbon monoxide contained in the third module effluent to produce a fourth module effluent having a reduced carbon monoxide concentration;

a fifth module positioned adjacent to the fourth module wherein a fifth process step occurs within the fifth module wherein the fifth process step is cooling the fourth module effluent to produce a fifth module effluent;

a sixth module positioned adjacent to the fifth module wherein a sixth process step occurs within the sixth module wherein the sixth process step is oxidizing at least some carbon monoxide to produce the hydrogen rich gas; and

feeding the hydrocarbon fuel successively through each of the modules in an axial direction to produce the hydrogen rich gas.

10. The process as described in claim 9 , wherein the hydrocarbon fuel is preheated by the second module, the fourth module, the fifth module, the sixth module, or any combination thereof.

11. The process as described in claim 9 , wherein the first module operates at a temperature ranging from about 550° C. to about 900° C.

12. The process as described in claim 9 , wherein the second module effluent is from about 200° C. to about 600° C.

13. The process as described in claim 9 , wherein the fourth module operates at a temperature ranging from about 150° C. to about 400° C.

14. The process as described in claim 9 , wherein the fourth module effluent is cooled to a temperature of from about 90° C. to about 150° C.

15. The process as described in claim 9 , wherein the sixth module operates at a temperature of from about 90° C. to about 150° C.

16. The process as described in claim 9 , wherein the hydrogen rich gas contains less than 50 ppm carbon monoxide.