Fuel cell system including ATO injector and method of operating the same

1. A fuel cell system, comprising:

a fuel cell stack;

an anode recuperator heat exchanger configured to receive an anode exhaust from the fuel cell stack;

an anode exhaust conduit configured to receive the anode exhaust from the anode recuperator;

a cathode exhaust conduit configured to receive a cathode exhaust from the fuel cell stack;

an anode tail gas oxidizer (ATO) surrounding the anode recuperator and configured to receive the cathode exhaust from the cathode exhaust conduit; and

an ATO injector located between the ATO and the anode exhaust conduit, the ATO injector comprising:

vanes configured to swirl the cathode exhaust provided from the cathode exhaust conduit; and

an arcuate body disposed between the anode exhaust conduit and the ATO and through which at least a portion of the anode exhaust is configured to flow from the anode exhaust conduit, the arcuate body comprising injection apertures configured to inject at least a portion of the anode exhaust into the swirled cathode exhaust flowing to the ATO;

wherein the arcuate body comprises a toroidal conduit having an arc measure of 360° taken along an outer surface of the toroidal conduit; and

wherein the toroidal conduit further comprises inner apertures configured to direct the first portion of the anode exhaust from the anode exhaust conduit into the toroidal conduit.

2. The system of claim 1 , wherein the inner apertures are larger than the injection apertures.

3. A fuel cell system, comprising:

a fuel cell stack;

an anode recuperator heat exchanger configured to receive an anode exhaust from the fuel cell stack;

an anode exhaust conduit configured to receive the anode exhaust from the anode recuperator;

a cathode exhaust conduit configured to receive a cathode exhaust from the fuel cell stack;

an anode tail gas oxidizer (ATO) surrounding the anode recuperator and configured to receive the cathode exhaust from the cathode exhaust conduit;

an ATO injector located between the ATO and the anode exhaust conduit, the ATO injector comprising:

vanes configured to swirl the cathode exhaust provided from the cathode exhaust conduit; and

an arcuate body disposed between the anode exhaust conduit and the ATO and through which at least a portion of the anode exhaust is configured to flow from the anode exhaust conduit, the arcuate body comprising injection apertures configured to inject at least a portion of the anode exhaust into the swirled cathode exhaust flowing to the ATO, wherein the arcuate body comprises a toroidal conduit having an arc measure of 360° taken along an outer surface of the toroidal conduit;

a supply tube configured to provide the anode exhaust from the anode exhaust conduit to the inside of the toroidal conduit; and

a valve configured to control the anode exhaust flow through the supply tube.

4. The system of claim 3 , wherein the valve is disposed outside a hotbox containing the anode recuperator heat exchanger, the anode exhaust conduit, the ATO, and the ATO injector.

5. The system of claim 3 , further comprising a carbon dioxide separator fluidly connected to the anode exhaust conduit and to the supply tube, wherein the carbon dioxide separator is configured to separate carbon dioxide from the anode exhaust.

6. The system of claim 5 , wherein the carbon dioxide separator comprises an electrochemical carbon dioxide separator.

7. The system of claim 5 , further comprising:

an anode exhaust cooler heat exchanger configured to heat an air inlet stream using the anode exhaust; and

a mixer configured to mix a portion of the anode exhaust with a fuel inlet stream flowing to the anode recuperator heat exchanger.

8. The system of claim 7 , wherein:

the anode exhaust conduit bypasses and is not directly fluidly connected to the toroidal conduit;

an inner surface of the toroidal conduit does not have any openings exposed to the anode exhaust conduit;

the carbon dioxide separator is located between the anode exhaust cooler heat exchanger and the mixer in a path of the anode exhaust; and

the anode exhaust conduit connects an outlet of the anode exhaust cooler heat exchanger to an inlet of the carbon dioxide separator.

9. The system of claim 8 , further comprising:

a purified anode exhaust conduit connected to a first outlet of the carbon dioxide separator;

a carbon dioxide outlet conduit connected to a second outlet of the carbon dioxide separator;

a splitter fluidly connected to the purified anode exhaust conduit; and

a mixer conduit fluidly connecting the splitter to the mixer, wherein the supply tube fluidly connects the splitter to the toroidal conduit.

10. The system of claim 3 , wherein the fuel cell stack comprises a solid oxide fuel cell stack.

11. A method of operating a fuel cell system, comprising:

providing at least a portion of a cathode exhaust from a fuel cell stack into an anode tail gas oxidizer (ATO) injector comprising a toroidal conduit containing injection conduits and vanes, wherein the fuel cell stack and the ATO injector are located in a hotbox;

swirling the cathode exhaust in the ATO injector using the vanes;

providing an entire anode exhaust from the fuel cell stack outside the hotbox past the ATO injector;

providing at least a first portion of the anode exhaust from the outside the hotbox into the ATO injector;

injecting at least the first portion of the anode exhaust from the toroidal conduit through the injection apertures into the swirled cathode exhaust; and

providing a mixture of the at least the first portion of the anode exhaust and the swirled cathode exhaust into an anode tail gas oxidizer (ATO).

12. The method of claim 11 , further comprising:

providing at least the first portion of the anode exhaust from outside the hotbox into the toroidal conduit of the ATO injector through plural supply tubes; and

controlling a flow of at least the first portion of the anode exhaust through the plural supply tubes using a valve located outside the hotbox.

13. The method of claim 11 , further comprising:

providing the anode exhaust from the fuel cell stack into an anode recuperator heat exchanger; and

exchanging heat between the anode exhaust and a fuel inlet stream.

14. The method of claim 13 , wherein:

the fuel inlet stream comprises a pure hydrogen fuel inlet stream or a hydrocarbon fuel inlet stream;

the ATO surrounds the anode recuperator heat exchanger;

the ATO injector is located above the ATO and the anode recuperator heat exchanger; and

the ATO injector is located above the ATO.

15. The method of claim 14 , further comprising:

passing all anode exhaust from the anode recuperator heat exchanger past the toroidal conduit and into a carbon dioxide separator located outside the hotbox to separate carbon dioxide from the anode exhaust;

passing the first portion of the anode exhaust from the carbon dioxide separator into the toroidal conduit; and

recycling the second portion of the anode exhaust from the carbon dioxide separator into a fuel inlet stream provided into the fuel cell stack.