Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Oxidant-enriched fuel cell system

Fuel cell systems that include at least one fuel cell stack adapted to receive a fuel stream containing hydrogen gas or other proton source, and an oxidant stream containing oxygen gas. The system includes an oxidant supply system adapted to deliver an enriched, or concentrated, oxidant stream to the fuel cell stack. In some embodiments, the oxidant supply system is adapted to receive an air stream and produce an oxygen-enriched stream therefrom. In some embodiments, the fuel cell system includes a water-recovery system adapted to recover water produced in the fuel cell stack, such as may be recovered from the cathode exhaust stream from the fuel cell stack. In some embodiments, the recovered water is utilized as at least a portion of a feed stream for the fuel cell system, such as for a reformer or electrolyzer that produces hydrogen used as fuel for the fuel cell stack.

STEAM REFORMING FUEL PROCESSOR, BURNER ASSEMBLY, AND METHODS OF OPERATING THE SAME

Systems and methods for producing hydrogen gas with a fuel processing system that includes a hydrogen-producing region that produces hydrogen gas from a feed stream and a heating assembly that consumes a fuel stream to produce a heated exhaust stream for heating the hydrogen-producing region. In some embodiments, the heating assembly heats the hydrogen-producing region to at least a minimum hydrogen-producing temperature. In some embodiments, the rate at which an air stream is delivered to the heating assembly is controlled to selectively increase or decrease the temperature of the heated exhaust stream. In some embodiments, the feed stream and the fuel stream both contain a carbon-containing feedstock and at least 25 wt % water. In some embodiments, the feed and fuel streams have the same composition.

FEEDSTOCK DELIVERY SYSTEM AND FUEL PROCESSING SYSTEMS CONTAINING THE SAME

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

A fuel processing system (10) incorporating a methanol steam reformer (13) comprising a catalyst bed (36) containing methanol steam reforming catalysts (34). The catalyst includes zinc oxide as an active component and may further include at least one of chromium oxide and calcium aluminate. The catalyst may not be pyrophoric and may not be reduced during use. Further the catalyst may include a sulfur-absorbent material and may not be active at temperatures below 275{C. The reforming catalyst bed (36) is air-permeable or air-accessible. Produced hydrogen gas is separated using hydrogen-permeable and/or hydrogen-selective membranes (46) to form hydrogen-rich stream (24) to be used in fuel cell systems and byproduct stream (26).

METHANOL STEAM REFORMING CATALYSTS, STEAM REFORMERS, AND FUEL CELL SYSTEMS INCORPORATING THE SAME

Hydrogen-producing fuel processing assemblies, heating assemblies, and methods of operating the same

Hydrogen-producing fuel processing assemblies, including steam reforming fuel processing assemblies, startup assemblies for use therein, and methods of operating the same. In some embodiments, the startup assemblies include a startup reforming region that is upstream from a primary, or second, hydrogen-producing reforming region. In some embodiments, the startup reforming region and primary reforming regions are both steam reforming regions. In some embodiments, the startup assembly further includes at least one of a vaporization region and a startup heating assembly. In some embodiments, the startup heating assembly is an electrically powered heating assembly, and the fuel processing assembly further includes a (primary) heating assembly that combusts a byproduct stream from the fuel processing assembly to produce a combustion exhaust stream. In some embodiments, the startup reforming region is adapted to produce a gaseous output stream that will remain a gas-phase stream even if cooled ...

STEAM REFORMING FUEL PROCESSOR, BURNER ASSEMBLY, AND METHODS OF OPERATING THE SAME

FUEL CELL SYSTEMS INCLUDING HYDROGEN-PRODUCING ASSEMBLIES

Hydrogen-producing assemblies, fuel cell systems including the same, methods of producing hydrogen gas, and methods of powering an energy-consuming device. Hydrogen--producing assemblies may include a monolithic body that defines at least a reforming conduit, in which a feed stream is catalyzed into a reformate gas stream containing hydrogen gas, and a burner conduit, in which a fuel-air stream is combusted. The monolithic body is constructed to conduct heat generated by the exothermic reaction of the combustion from the burner conduit to the reformer conduit. In some hydrogen-producing assemblies, the monolithic body further defines a vaporizer conduit, in which liquid portions of the feed stream are vaporized prior to being delivered to the reformer conduit. In such embodiments, the monolithic body is constructed to conduct heat from the burner conduit to the vaporizer conduit. Hydrogen-producing assemblies may be incorporated into a fuel cell system that is configured to power an energy-consuming ...

METHANOL STEAM REFORMING CATALYSTS, STEAM REFORMERS, AND FUEL CELL SYSTEMS INCORPORATING THE SAME

A fuel processing system (10) incorporating a methanol steam reformer (13) comprising a catalyst bed (36) containing methanol steam reforming catalysts (34). The catalyst includes zinc oxide as an active component and may further include at least one of chromium oxide and calcium aluminate. The catalyst may not be pyrophoric and may not be reduced during use. Further the catalyst may include a sulfur-absorbent material and may not be active at temperatures below 275°C. The reforming catalyst bed (36) is air-permeable or air- accessible. Produced hydrogen gas is separated using hydrogen-permeable and/or hydrogen-selective membranes (46) to form hydrogen-rich stream (24) to be used in fuel cell systems and byproduct stream (26). © KIPO & WIPO 2007 ...

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Feedstock delivery system and fuel processing systems containing the same

Steam reforming fuel processor, burner assembly, and methods of operating the same

Fuel processing systems with thermally integrated componentry

Hydrogen-producing assemblies, fuel cell systems including the same, methods of producing hydrogen gas, and methods of powering an energy-consuming device. Hydrogen-producing assemblies may include a monolithic body that defines at least a reforming conduit, and in some embodiments a plurality of reforming conduits, in which a feed stream is catalyzed into a reformate gas stream containing hydrogen gas, and a burner conduit, in which a fuel-air stream is combusted. The monolithic body is constructed to conduct heat generated by the exothermic reaction of the combustion from the burner conduit to the reformer conduit. In some hydrogen-producing assemblies, the monolithic body further defines a vaporizing conduit, in which liquid portions of the feed stream are vaporized prior to being delivered to the reformer conduit, and the monolithic body may be constructed to conduct heat from the burner conduit to the vaporizing conduit.

Monitoring and control of fuel cell purge to emit non-flammable exhaust streams

METHANOL STEAM REFORMING CATALYSTS, STEAM REFORMERS, AND FUEL CELL SYSTEMS INCORPORATING THE SAME

A fuel processing system (10) incorporating a methanol steam reformer (13) comprising a catalyst bed (36) containing methanol steam reforming catalysts (34). The catalyst includes zinc oxide as an active component and may further include at least one of chromium oxide and calcium aluminate. The catalyst may not be pyrophoric and may not be reduced during use. Further the catalyst may include a sulfur-absorbent material and may not be active at temperatures below 275°C. The reforming catalyst bed (36) is air-permeable or air- accessible. Produced hydrogen gas is separated using hydrogen-permeable and/or hydrogen-selective membranes (46) to form hydrogen-rich stream (24) to be used in fuel cell systems and byproduct stream (26). © KIPO & WIPO 2007 ...

Hydrogen-producing fuel processing assemblies, heating assemblies, and methods of operating the same

Hydrogen-producing fuel processing assemblies, including steam reforming fuel processing assemblies, startup assemblies for use therein, and methods of operating the same. In some embodiments, the startup assemblies include a startup reforming region that is upstream from a primary, or second, hydrogen-producing reforming region. In some embodiments, the startup reforming region and primary reforming regions are both steam reforming regions. In some embodiments, the startup assembly further includes at least one of a vaporization region and a startup heating assembly. In some embodiments, the startup heating assembly is an electrically powered heating assembly, and the fuel processing assembly further includes a (primary) heating assembly that combusts a byproduct stream from the fuel processing assembly to produce a combustion exhaust stream. In some embodiments, the startup reforming region is adapted to produce a gaseous output stream that will remain a gas-phase stream even if cooled below a minimum hydrogen-producing temperature.

Fuel cell systems and methods for passively increasing hydrogen recovery through vacuum-assisted pressure swing adsorption

PSA assemblies with at least one energy recovery assembly, as well as hydrogen-generation assemblies and/or fuel cell systems containing the same, and methods of operating the same. The energy recovery assemblies are configured to recover mechanical energy from the product hydrogen stream and to apply the recovered mechanical energy to one or more components of the PSA assembly, the hydrogen-generation assembly, and/or the energy producing system. In some embodiments, the energy recovery assembly includes a gas motor configured to recover mechanical energy from the product hydrogen stream produced by the PSA assembly. In some embodiments, the gas motor operates among a plurality of operating states based, at least in part, on the pressure of the product hydrogen stream. In some embodiments, the energy recovery assembly is configured to apply the recovered mechanical energy to at least a vacuum pump.

Fuel cell systems and methods for passively increasing hydrogen recovery through vacuum-assisted pressure swing adsorption

Steam reforming fuel processor, burner assembly, and methods of operating the same

Systems and methods for producing hydrogen gas with a fuel processing system that includes a hydrogen-producing region that produces hydrogen gas from a feed stream and a heating assembly that consumes a fuel stream to produce a heated exhaust stream for heating the hydrogen-producing region. In some embodiments, the heating assembly heats the hydrogen-producing region to at least a minimum hydrogen-producing temperature. In some embodiments, the feed stream and the fuel stream both contain a carbon-containing feedstock and at least 25 wt % water. In some embodiments, at least one of the feed and fuel streams contain at least one additional component. In some embodiments, the feed and fuel streams have the same composition. In some embodiments, the feed and fuel streams are drawn or obtained from a common source or supply, and in some embodiments as a liquid stream that is selectively apportioned to form the feed and fuel streams.

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Methanol steam reforming catalysts, and steam reformers and fuel cell systems incorporating the same. In some embodiments, the methanol steam reforming catalyst includes zinc oxide as an active component. In some embodiments, the methanol steam reforming catalyst further includes at least one of chromium oxide and calcium aluminate. In some embodiments, the methanol steam reforming catalyst is not pyrophoric. Similarly, in some embodiments, steam reformers including a reforming catalyst according to the present disclosure may include an air-permeable or air-accessible reforming catalyst bed. In some embodiments, the methanol steam reforming catalyst is not reduced during use. In some embodiments, the methanol reforming catalysts are not active at temperatures below 275° C. In some embodiments, the methanol steam reforming catalyst includes a sulfur-absorbent material. Steam reformers, reforming systems, fuel cell systems and methods of using the reforming catalysts are also disclosed.

STEAM REFORMING FUEL PROCESSOR, BURNER ASSEMBLY, AND METHODS OF OPERATING THE SAME

Systems and methods for producing hydrogen gas with a fuel processing system that includes a hydrogen-producing region that produces hydrogen gas from a feed stream and a heating assembly that consumes a fuel stream to produce a heated exhaust stream for heating the hydrogen-producing region. In some embodiments, the heating assembly heats the hydrogen-producing region to at least a minimum hydrogen-producing temperature. In some embodiments, the rate at which an air stream is delivered to the heating assembly is controlled to selectively increase or decrease the temperature of the heated exhaust stream. In some embodiments, the feed stream and the fuel stream both contain a carbon-containing feedstock and at least 25 wt % water. In some embodiments, the feed and fuel streams have the same composition.

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Steam reforming fuel processor, burner assembly, and methods of operating the same

Diffusion and atomizing burner assemblies and fuel processing and fuel cell systems containing the same. The burner assembly receives at least one liquid and/or gaseous fuel streams, mixes the stream with air, and combusts the mixed stream to provide heat for a fuel processor. In some embodiment, the burner assembly receives at least one combustible fuel stream produced by the fuel processing and/or fuel cell system. In some embodiment, the burner assembly receives a fuel stream having the same composition as a stream that is delivered for non-combustion purposes to another portion of the fuel processing and/or fuel cell system. In some embodiment, the burner assembly receives and vaporizes a fuel stream that includes the same carbon-containing feedstock and/or has the same overall composition as the feed stream from which the stream reformer or other fuel processor produces hydrogen gas. Methods of use are also disclosed.

Monitoring and control of fuel cell purge to emit non-flammable exhaust streams

Systems and methods for monitoring and/or controlling fuel cell exhaust to provide a non-flammable exhaust stream. In some embodiments, operation of the fuel cell system is regulated to provide an exhaust stream that has a maximum flammability that is less than a predetermined fractional threshold of the lower flammability limit for the gases contained therein. In some embodiments, the systems and methods utilize the current produced by the fuel cell, or fuel cell stack, to monitor and/or regulate the flammability of the fuel cell exhaust stream. In some embodiments, the fuel cell system includes one or more controllers that are adapted to monitor the flammability of the exhaust stream from the fuel cell stack and/or to regulate the operation of the fuel cell system responsive thereto. In some embodiments, the operation and/or duty cycle of at least an anode purge valve is regulated or controlled responsive to the measured current.

Systems and methods for initiating operation of pressure swing adsorption systems and hydrogen-producing fuel processing systems incorporating the same

Pressure swing adsorption (PSA) assemblies with optimized startup times, as well as to hydrogen-generation assemblies and/or fuel cell systems containing the same, and methods of operating the same. Startup and shutdown methods for a PSA assembly, and optionally an associated fuel processing system, are disclosed to provide for shortened startup times. The PSA assemblies may be in fluid communication with a hydrogen source that may be used or otherwise configured or controlled to purge the PSA adsorbent columns of adsorbents during startup and/or shutdown procedures, the hydrogen source additionally or alternatively may be used or otherwise configured or controlled to charge the columns with hydrogen for idling in a pressurized state. The use of this hydrogen source, together with specific startup and shutdown methodologies, provides for reducing the startup time of the PSA assembly.

Systems and methods for initiating operation of pressure swing adsorption systems and hydrogen-producing fuel processing systems incorporating the same

FUEL CELL SYSTEMS WITH WATER RECOVERY FROM FUEL CELL EFFLUENT

Fuel cell systems that use a desiccant to recover water from fuel cell effluent. In some embodiments, the fuel cell system may include one or more fuel cells configured to generate electrical output from a supplied fuel and an oxidant while emitting effluent. The fuel cell system also may include a desiccant disposed downstream of the one or more fuel cells. The desiccant may bind water from at least a portion of the effluent. Heat then may be generated to release bound water from the desiccant. The heat may be generated by combustion of an exhausted fuel from the fuel cells and/or by combustion catalyzed by a combustion catalyst disposed downstream of the fuel cells.

Hydrogen-producing assemblies,fuel cell systems including the same,and methods of producing hydrogen gas

HYDROGEN-PRODUCING FUEL PROCESSING ASSEMBLIES, HEATING ASSEMBLIES, AND METHODS OF OPERATING THE SAME

Hydrogen-producing fuel processing assemblies, including steam reforming fuel processing assemblies, startup assemblies for use therein, and methods of operating the same. In some embodiments, the startup assemblies include a startup reforming region that is upstream from a primary, or second, hydrogen-producing reforming region. In some embodiments, the startup reforming region and primary reforming regions are both steam reforming regions. In some embodiments, the startup assembly further includes at least one of a vaporization region and a startup heating assembly. In some embodiments, the startup heating assembly is an electrically powered heating assembly, and the fuel processing assembly further includes a (primary) heating assembly that combusts a byproduct stream from the fuel processing assembly to produce a combustion exhaust stream. In some embodiments, the startup reforming region is adapted to produce a gaseous output stream that will remain a gas-phase stream even if cooled ...

Systems and methods for initiating operation of pressure swing adsorption systems and hydrogen-producing fuel processing systems incorporating the same

Pressure swing adsorption (PSA) assemblies with optimized startup times, as well as to hydrogen-generation assemblies and/or fuel cell systems containing the same, and methods of operating the same. Startup and shutdown methods for a PSA assembly, and optionally an associated fuel processing system, are disclosed to provide for shortened startup times. The PSA assemblies may be in fluid communication with a hydrogen source that may be used or otherwise configured or controlled to purge the PSA adsorbent columns of adsorbents during startup and/or shutdown procedures, the hydrogen source additionally or alternatively may be used or otherwise configured or controlled to charge the columns with hydrogen for idling in a pressurized state. The use of this hydrogen source, together with specific startup and shutdown methodologies, provides for reducing the startup time of the PSA assembly.

HYDROGEN-PRODUCING ASSEMBLIES, FUEL CELL SYSTEMS INCLUDING THE SAME, METHODS OF PRODUCING HYDROGEN GAS, AND METHODS OF POWERING AN ENERGY-CONSUMING DEVICE

Hydrogen-producing assemblies, fuel cell systems including the same, methods of producing hydrogen gas, and methods of powering an energy-consuming device. Hydrogen-producing assemblies may include a monolithic body that defines at least a reforming conduit, in which a feed stream is catalyzed into a reformate gas stream containing hydrogen gas, and a burner conduit, in which a fuel-air stream is combusted. The monolithic body is constructed to conduct heat generated by the exothermic reaction of the combustion from the burner conduit to the reformer conduit. In some hydrogen-producing assemblies, the monolithic body further defines a vaporizer conduit, in which liquid portions of the feed stream are vaporized prior to being delivered to the reformer conduit. In such embodiments, the monolithic body is constructed to conduct heat from the burner conduit to the vaporizer conduit. Hydrogen-producing assemblies may be incorporated into a fuel cell system that is configured to power an energy-consuming ...

METHANOL STEAM REFORMING CATALYSTS, STEAM REFORMERS, AND FUEL CELL SYSTEMS INCORPORATING THE SAME

Methanol steam reforming catalysts, and steam reformers and fuel cell systems incorporating the same. In some embodiments, the methanol steam reforming catalyst includes zinc oxide as an active component. In some embodiments, the methanol steam reforming catalyst further includes at least one of chromium oxide and calcium aluminate. In some embodiments, the methanol steam reforming catalyst is not pyrophoric. Similarly, in some embodiments, steam reformers including a reforming catalyst according to the present disclosure may include an air-permeable or air-accessible reforming catalyst bed. In some embodiments, the methanol steam reforming catalyst is not reduced during use. In some embodiments, the methanol reforming catalysts are not active at temperatures below 275° C. In some embodiments, the methanol steam reforming catalyst includes a sulfur-absorbent material. Steam reformers, reforming systems, fuel cell systems and methods of using the reforming catalysts are also disclosed.

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Methanol steam reforming catalysts, and steam reformers and fuel cell systems incorporating the same. In some embodiments, the methanol steam reforming catalyst includes zinc oxide as an active component. In some embodiments, the methanol steam reforming catalyst further includes at least one of chromium oxide and calcium aluminate. In some embodiments, the methanol steam reforming catalyst is not pyrophoric. Similarly, in some embodiments, steam reformers including a reforming catalyst according to the present disclosure may include an air-permeable or air-accessible reforming catalyst bed. In some embodiments, the methanol steam reforming catalyst is not reduced during use. In some embodiments, the methanol reforming catalysts are not active at temperatures below 275 DEG C. In some embodiments, the methanol steam reforming catalyst includes a sulfur-absorbent material. Steam reformers, reforming systems, fuel cell systems and methods of using the reforming catalysts are also disclosed ...

Steam reforming fuel processor, burner assembly, and methods of operating the same

Systems and methods for producing hydrogen gas with a fuel processing system that includes a hydrogen-producing region that produces hydrogen gas from a feed stream and a heating assembly that consumes a fuel stream to produce a heated exhaust stream for heating the hydrogen-producing region. In some embodiments, the heating assembly heats the hydrogen-producing region to at least a minimum hydrogen-producing temperature. In some embodiments, the rate at which an air stream is delivered to the heating assembly is controlled to selectively increase or decrease the temperature of the heated exhaust stream. In some embodiments, the feed stream and the fuel stream both contain a carbon-containing feedstock and at least 25 wt % water. In some embodiments, the feed and fuel streams have the same composition.

Monitoring and control of fuel cell purge to emit non-flammable exhaust streams

Systems and methods for monitoring and/or controlling fuel cell exhaust to provide a non-flammable exhaust stream. In some embodiments, operation of the fuel cell system is regulated to provide an exhaust stream that has a maximum flammability that is less than a predetermined fractional threshold of the lower flammability limit for the gases contained therein. In some embodiments, the systems and methods utilize the current produced by the fuel cell, or fuel cell stack, to monitor and/or regulate the flammability of the fuel cell exhaust stream. In some embodiments, the fuel cell system includes one or more controllers that are adapted to monitor the flammability of the exhaust stream from the fuel cell stack and/or to regulate the operation of the fuel cell system responsive thereto. In some embodiments, the operation and/or duty cycle of at least an anode purge valve is regulated or controlled responsive to the measured current.

Steam reforming fuel processor, burner assembly, and methods of operating the same

Systems and methods for producing hydrogen gas with a fuel processing system that includes a hydrogen-producing region that produces hydrogen gas from a feed stream and a heating assembly that consumes a fuel stream to produce a heated exhaust stream for heating the hydrogen-producing region. In some embodiments, the heating assembly heats the hydrogen-producing region to at least a minimum hydrogen-producing temperature. In some embodiments, the rate at which an air stream is delivered to the heating assembly is controlled to selectively increase or decrease the temperature of the heated exhaust stream. In some embodiments, the feed stream and the fuel stream both contain a carbon-containing feedstock and at least 25 wt % water. In some embodiments, the feed and fuel streams have the same composition.

Fuel processing systems with thermally integrated componentry

Fuel cell systems including hydrogen-producing assemblies

Hydrogen-producing assemblies, fuel cell systems including the same, methods of producing hydrogen gas, and methods of powering an energy-consuming device Hydrogen-producing assemblies may include a monolithic body that defines at least a reforming conduit, in which a feed stream is catalyzed into a reformate gas stream containing hydrogen gas, and a burner conduit, in which a fuel-air stream is combusted The monolithic body conducts heat generated by the exothermic reaction of the combustion from the burner conduit to the reformer conduit In some hydrogen-producing assemblies, the monolithic body further defines a vaporizer conduit, in which liquid portions of the feed stream are vaporized prior to being delivered to the reformer conduit, and the monolithic body conducts heat from the burner conduit to the vaporizer conduit Hydrogen-producing assemblies may be incorporated into a fuel cell system configured to power an energy-consuming device.

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Methanol steam reforming catalysts, and steam reformers and fuel cell systems incorporating the same. In some embodiments, the methanol steam reforming catalyst includes zinc oxide as an active component. In some embodiments, the methanol steam reforming catalyst further includes at least one of chromium oxide and calcium aluminate. In some embodiments, the methanol steam reforming catalyst is not pyrophoric. Similarly, in some embodiments, steam reformers including a reforming catalyst according to the present disclosure may include an air-permeable or air-accessible reforming catalyst bed. In some embodiments, the methanol steam reforming catalyst is not reduced during use. In some embodiments, the methanol reforming catalysts are not active at temperatures below 275° C. In some embodiments, the methanol steam reforming catalyst includes a sulfur-absorbent material. Steam reformers, reforming systems, fuel cell systems and methods of using the reforming catalysts are also disclosed.

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Methanol steam reforming catalysts, and steam reformers and fuel cell systems incorporating the same. In some embodiments, the methanol steam reforming catalyst includes zinc oxide as an active component. In some embodiments, the methanol steam reforming catalyst further includes at least one of chromium oxide and calcium aluminate. In some embodiments, the methanol steam reforming catalyst is not pyrophoric. Similarly, in some embodiments, steam reformers including a reforming catalyst according to the present disclosure may include an air-permeable or air-accessible reforming catalyst bed. In some embodiments, the methanol steam reforming catalyst is not reduced during use. In some embodiments, the methanol reforming catalysts are not active at temperatures below 275° C. In some embodiments, the methanol steam reforming catalyst includes a sulfur-absorbent material. Steam reformers, reforming systems, fuel cell systems and methods of using the reforming catalysts are also disclosed.

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Methanol steam reforming catalysts, and steam reformers and fuel cell systems incorporating the same. In some embodiments, the methanol steam reforming catalyst includes zinc oxide as an active component. In some embodiments, the methanol steam reforming catalyst further includes at least one of chromium oxide and calcium aluminate. In some embodiments, the methanol steam reforming catalyst is not pyrophoric. Similarly, in some embodiments, steam reformers including a reforming catalyst according to the present disclosure may include an air-permeable or air-accessible reforming catalyst bed. In some embodiments, the methanol steam reforming catalyst is not reduced during use. In some embodiments, the methanol reforming catalysts are not active at temperatures below 275° C. In some embodiments, the methanol steam reforming catalyst includes a sulfur-absorbent material. Steam reformers, reforming systems, fuel cell systems and methods of using the reforming catalysts are also disclosed.

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Methanol steam reforming catalysts, and steam reformers and fuel cell systems incorporating the same. In some embodiments, the methanol steam reforming catalyst includes zinc oxide as an active component. In some embodiments, the methanol steam reforming catalyst further includes at least one of chromium oxide and calcium aluminate. In some embodiments, the methanol steam reforming catalyst is not pyrophoric. Similarly, in some embodiments, steam reformers including a reforming catalyst according to the present disclosure may include an air-permeable or air-accessible reforming catalyst bed. In some embodiments, the methanol steam reforming catalyst is not reduced during use. In some embodiments, the methanol reforming catalysts are not active at temperatures below 275° C. In some embodiments, the methanol steam reforming catalyst includes a sulfur-absorbent material. Steam reformers, reforming systems, fuel cell systems and methods of using the reforming catalysts are also disclosed.

Steam reforming fuel processor, burner assembly, and methods of operating the same

Diffusion and atomizing burner assemblies and fuel processing and fuel cell systems containing the same. The burner assembly receives at least one liquid and/or gaseous fuel stream, mixes the stream with air, and combusts the mixed stream to provide heat for a fuel processor. In some embodiments, the burner assembly receives at least one combustible fuel stream produced by the fuel processing and/or fuel cell system. In some embodiments, the burner assembly receives a fuel stream having the same composition as a stream that is delivered for non-combustion purposes to another portion of the fuel processing and/or fuel cell system. In some embodiments, the burner assembly receives and vaporizes a fuel stream that includes the same carbon-containing feedstock and/or has the same overall composition as the feed stream from which the steam reformer or other fuel processor produces hydrogen gas. Methods of use are also disclosed.

Feedstock delivery system and fuel processing systems containing the same

A fuel processing system includes a feedstock delivery system adapted to produce a pressurized feed stream containing at least one combustible carbon-containing feedstock. The delivery system includes a feedstock reservoir having a compartment adapted to store under pressure in a liquid phase a volume of a combustible carbon containing feedstock, a pressurization assembly adapted to pressurize the reservoir by delivering a pressurized gas stream to the compartment of the reservoir, a sensor assembly including one or more sensors adapted to detect whether a concentration of oxygen gas in the compartment exceeds the flammable or explosive threshold of the feedstock, and a controller adapted to compare a measured value of oxygen gas detected by the sensor assembly to at least one threshold value. A hydrogen-producing fuel processor is adapted to receive the pressurized feed stream and utilize the feed stream to produce a mixed gas stream containing hydrogen gas therefrom.

Methanol steam reforming catalysts, steam reformers, and fuel cell systems incorporating the same

Steam reforming fuel processor, burner assembly, and methods of operating the same

A burner assembly (400') receiving at least one liquid and/or gaseous fuel stream (408) mixing said stream with air (410) and combusting the mixed stream to provide heat for a fuel processor. The burner assembly fuel stream (408) may originate as at least one combustible stream produced by fuel processing and/or fuel cell system and have the same composition as a stream that is delivered for non-combustion purposes to another portion of the fuel processing and/or fuel cell system. Additionally the burner assembly (400') may receive and vaporize a fuel stream (82) that includes the same carbon-containing feedstock and/or has the same overall composition as feed stream from which the fuel processor, e.g. steam reformer, produces hydrogen gas.

Systems and methods for initiating operation of pressure swing adsorption systems and hydrogen-producing fuel processing systems incorporating the same

Pressure swing adsorption (PSA) assemblies with optimized startup times, as well as to hydrogen-generation assemblies and/or fuel cell systems containing the same, and methods of operating the same. Startup and shutdown methods for a PSA assembly, and optionally an associated fuel processing system, are disclosed to provide for shortened startup times. The PSA assemblies may be in fluid communication with a hydrogen source that may be used or otherwise configured or controlled to purge the PSA adsorbent columns of adsorbents during startup and/or shutdown procedures, the hydrogen source additionally or alternatively may be used or otherwise configured or controlled to charge the columns with hydrogen for idling in a pressurized state. The use of this hydrogen source, together with specific startup and shutdown methodologies, provides for reducing the startup time of the PSA assembly.

Feedstock delivery system and fuel processing systems containing the same

Feedstock delivery system (17) for fuel processor (12), includes at least one pressurized tank or other reservoir (60) that is adapted to store in liquid form a feedstock (64) for the fuel processor. The delivery system further (17) includes a pressurization assembly (70) that is adapted to pressurize the reservoir (60) by delivering a stream (74) of pressurized gas (78) thereto. The gas (78) is at least substantially comprised of nitrogen or other inert gases (82) and it may be a nitrogen-enriched or oxygen-reduced air stream (84). The delivery system (17) may include a sensor assembly (91) that is adapted to monitor the concentration of oxygen in the reservoir (60) and/or being delivered to the reservoir (60). The delivery system (17) may include a pump-less delivery system (72) that regulates the delivery, under pressure, of the feedstock (64) from the reservoir (60) to the fuel processor (12).

Oxidant-enriched fuel cell system

Fuel cell systems that include at least one fuel cell stack adapted to receive a fuel stream containing hydrogen gas or other proton source, and an oxidant stream containing oxygen gas. The systems include an oxidant supply system adapted to deliver an enriched, or concentrated, oxidant stream to the fuel cell stack. In some embodiments, the oxidant supply system is adapted to receive an air stream and produce an oxygen-enriched stream therefrom. In some embodiments, the fuel cell system includes a water-recovery system adapted to recover water produced in the fuel cell stack, such as may be recovered from the cathode exhaust stream from the fuel cell stack. In some embodiments, the recovered water is utilized as at least a portion of a feed stream for the fuel cell system, such as for a reformer or electrolyzer that produces hydrogen used as fuel for the fuel cell stack.

Steam reforming fuel processor, burner assembly, and methods of operating the same

A fuel processor includes a hydrogen-producing region and a burner assembly. The hydrogen-producing region is adapted to receive a feed stream and to produce a mixed gas stream containing hydrogen gas and other gases therefrom. The burner assembly is adapted to produce a heated exhaust stream for heating at least the hydrogen-producing region of the fuel processor. The burner assembly is also adapted to receive a combustible fuel stream and an air stream and to combust the fuel and air streams to produce the heated exhaust stream. The fuel processor further includes means for controlling the amount of heat produced by the burner assembly by controlling the rate at which the air stream is delivered to the burner assembly.

Fuel cell systems and methods for passively increasing hydrogen recovery through vacuum-assisted pressure swing adsorption

PSA assemblies with at least one energy recovery assembly, as well as hydrogen-generation assemblies and/or fuel cell systems containing the same, and methods of operating the same. The energy recovery assemblies are configured to recover mechanical energy from the product hydrogen stream and to apply the recovered mechanical energy to one or more components of the PSA assembly, the hydrogen-generation assembly, and/or the energy producing system. In some embodiments, the energy recovery assembly includes a gas motor configured to recover mechanical energy from the product hydrogen stream produced by the PSA assembly. In some embodiments, the gas motor operates among a plurality of operating states based, at least in part, on the pressure of the product hydrogen stream. In some embodiments, the energy recovery assembly is configured to apply the recovered mechanical energy to at least a vacuum pump.

Fuel cell systems with water recovery

Fuel cell systems that use a desiccant to recover water from fuel cell effluent. In some embodiments, the fuel cell system may include one or more fuel cells configured to generate electrical output from a supplied fuel and an oxidant while emitting effluent. The fuel cell system also may include a desiccant disposed downstream of the one or more fuel cells. The desiccant may bind water from at least a portion of the effluent. Heat then may be generated to release bound water from the desiccant. The heat may be generated by combustion of an exhausted fuel from the fuel cells and/or by combustion catalyzed by a combustion catalyst disposed downstream of the fuei cells.

Monitoreo y control de purga de celdas de combustible para emitir corrientes no inflamables de escape.

Sistemas y métodos para monitorizar y/o controlar el escape de celdas de combustible para proporcionar una corriente no inflamable de escape. En algunas modalidades, la operación del sistema de celdas de combustible se regula para proporcionar una corriente de escape que tiene una inflamabilidad máxima que es menor que un umbral fraccional predeterminado del límite inferior de inflamabilidad para los gases contenidos en la misma. En algunas modalidades, los sistemas y métodos utilizan la corriente producida por la celda de combustible, o pila de celdas de combustible, para monitorizar y/o regular la inflamabilidad de la corriente de escape de celda de combustible. En algunas modalidades, el sistema de celdas de combustible incluye uno o más controladores que se adaptan para monitorizar la inflamabilidad de la corriente de escape desde la pila de celdas de combustible y/o para regular la operación del sistema de celdas de combustible sensible a la misma. En algunas modalidades, la operación y/o ciclo de trabajo de al menos una válvula de purga de ánodo se regula o controla en respuesta a la corriente medida.

Steam reforming fuel processor, burner assembly, and methods of operating the same

A fuel processor includes: a hydrogen-producing region adapted to receive a feed stream and produce a mixed gas stream containing hydrogen gas and other gases therefrom; at least one separation region adapted to receive at least a portion of the mixed gas stream and produce a hydrogen-rich stream containing at least substantially pure hydrogen gas and at least one byproduct stream containing at least a substantial portion of the other gases; and a diffusion burner assembly adapted to produce a heated exhaust stream for heating at least the hydrogen-producing region. The burner assembly is adapted to receive an air stream and a combustible fuel stream, and includes a diffusion region adapted to mix the fuel stream and the air stream to form an oxygenated combustible fuel stream, a combustion region adapted to receive the oxygenated combustible fuel stream, and at least one ignition region adapted to initiate combustion thereof.

Fuel processing systems with thermally integrated componentry

Hydrogen-producing assemblies, fuel cell systems including the same, methods of producing hydrogen gas, and methods of powering an energy-consuming device. Hydrogen- producing assemblies may include a monolithic body that defines at least a reforming conduit, and in some embodiments a plurality of reforming conduits, in which a feed stream is catalyzed into a reformate gas stream containing hydrogen gas, and a burner conduit, in which a fuel-air stream is combusted. The monolithic body is constructed to conduct heat generated by the exothermic reaction of the combustion from the burner conduit to the reformer conduit. In some hydrogen-producing assemblies, the monolithic body further defines a vaporizing conduit, in which liquid portions of the feed stream are vaporized prior to being delivered to the reformer conduit, and the monolithic body may be constructed to conduct heat from the burner conduit to the vaporizing conduit.

Fuel cell systems and methods for passively increasing hydrogen recovery through vacuum-assisted pressure swing adsorption

PSA assemblies with at least one energy recovery assembly, as well as hydrogen-generation assemblies and/or fuel cell systems containing the same, and methods of operating the same. The energy recovery assemblies are configured to recover mechanical energy from the product hydrogen stream and to apply the recovered mechanical energy to one or more components of the PSA assembly, the hydrogen-generation assembly, and/or the energy producing system. In some embodiments, the energy recovery assembly includes a gas motor configured to recover mechanical energy from the product hydrogen stream produced by the PSA assembly. In some embodiments, the gas motor operates among a plurality of operating states based, at least in part, on the pressure of the product hydrogen stream. In some embodiments, the energy recovery assembly is configured to apply the recovered mechanical energy to at least a vacuum pump.

Fuel cell systems and methods for passively increasing hydrogen recovery through vacuum-assisted pressure swing adsorption

PSA assemblies with at least one energy recovery assembly, as well as hydrogen-generation assemblies and/or fuel cell systems containing the same, and methods of operating the same. The energy recovery assemblies are configured to recover mechanical energy from the product hydrogen stream and to apply the recovered mechanical energy to one or more components of the PSA assembly, the hydrogen-generation assembly, and/or the energy producing system. In some embodiments, the energy recovery assembly includes a gas motor configured to recover mechanical energy from the product hydrogen stream produced by the PSA assembly. In some embodiments, the gas motor operates among a plurality of operating states based, at least in part, on the pressure of the product hydrogen stream. In some embodiments, the energy recovery assembly is configured to apply the recovered mechanical energy to at least a vacuum pump.