Abstract: A plasmatron-catalyst system. The system generates hydrogen-rich gas and comprises a plasmatron and at least one catalyst for receiving an output from the plasmatron to produce hydrogen-rich gas. In a preferred embodiment, the plasmatron receives as an input air, fuel and water/steam for use in the reforming process. The system increases the hydrogen yield and decreases the amount of carbon monoxide.

Abstract: The invention provides an apparatus for online and on-site tracer generation for tagging natural gas stored in underground storage fields wherein feedstock is drawn from a feedstock source. The feedstock undergoes initial analysis to determine hydrocarbons levels. The feedstock then undergoes reaction to produce tracers such as ethylene, propylene, acetylene hydrogen and carbon monoxide. The feedstock is then analyzed to determine post reaction tracer concentration. The feedstock including generated tracers is then introduced back into the feedstock stream. Tracer levels in the pre-reaction or initial analysis of feedstock are compared with tracer levels in the post-reaction feedstock and the rate of flow of feedstock through the system is adjusted to achieve a predetermined level of tracer concentration. The level of tracer concentration will then be used to identify the particular natural gas charge in a storage field.

Abstract: This invention relates to a compact apparatus for generating hydrogen. More particularly, this invention relates to a compact hydrogen generating apparatus suitable for use in conjunction with a fuel cell. The compact hydrogen generating apparatus comprises a fuel processor reactor having an integrated pre-reforming zone embedded within a secondary reforming zone.

Abstract: A method and catalysts for producing a hydrogen-rich syngas are disclosed. According to the method a CO-containing gas contacts a water gas shift (WGS) catalyst, in the presence of water, preferably at a temperature of less than about 450° C. to produce a hydrogen-rich syngas.

Abstract: A stand-alone fuel processor (10) for producing hydrogen from a hydrocarbon fuel for a fuel cell engine in a vehicle. The fuel processor (10) includes a primary reactor (14) that dissociates hydrogen and other by-products from the hydrocarbon fuel as a reformate gas. The reformate gas is applied to a WGS reactor (48) to convert carbon monoxide and water to hydrogen and carbon dioxide. The WGS reactor (14) may include an adsorbent for adsorbing carbon monoxide. The reformate gas from the WGS reactor (48) is then sent to a rapid-cycle PSA device (12) for adsorbing the undesirable by-products in the gas and generates a stream of pure hydrogen. A liquid water separator (70) separates water from the reformate gas before it is applied to the PSA device (12). The PSA device (12) uses a portion of the separated hydrogen as a desorbing gas to purify the adsorbent in the PSA device (12). The by-products of the reformate gas can be used as a fuel in a combustor (30) that generates heat for the primary reactor (14).

Abstract: Low-energy hydrogen production is disclosed. A reforming exchanger is placed in parallel with a partial oxidation reactor in a new hydrogen plant with improved efficiency and reduced steam export, or in an existing hydrogen plant where the hydrogen capacity can be increased by as much as 20-30 percent with reduced export of steam from the hydrogen plant.

Abstract: An apparatus for carrying out a multi-step process of converting hydrocarbon fuel to a substantially pure hydrogen gas feed includes a plurality of reaction zones arranged in an insulated, box-shaped, compact fuel processor. The multi-step process includes preheating the hydrocarbon fuel utilizing integration with the inherent exothermic processes utilized with the fuel processor, reacting the preheated hydrocarbon fuel to form the hydrogen rich gas, and purifying the hydrogen rich gas to produce a gas that is suitable for consumption in a fuel cell.

Abstract: The method according to the invention concerns an anaerobic conversion of biomass into biogas in separated processes of hydrolysis and methane fermentation of biomass by means of methane mesophile, thermophile and psychrophile bacteria, contained in returned reflux. Cleaned biogas undergoes decomposition into methane and carbon dioxide. From part of methane and biogas standard gas fuel is produced, used for the engine of a current generating unit and a thermoregenerative cell generating electrical energy and heat. The system according to the invention consists of a system of preparation of biomass (1) connected to a hydrolyser (2) and then to a series system of fermentation tanks and a composter (1), which co-operates with a system of returning and enriching reflux (4). A tank for raw biogas (5) is connected to a system for cleaning biogas (6) and then to a tank for cleaned biogas (7) connected to a system of biogas decomposition (8) and a gas mixer (11).

Abstract: There is disclosed a metal particle-dispersed composite oxide comprising a matrix material containing a composite oxide comprising a non-reducible metal oxide and an easily reducible metal oxide, the composite oxide containing 0.01 to 0.25 mol % of at least one additive metal selected from Al, Sc, Cr, B, Fe, Ga, In, Lu, Nb and Si, surface metal particles precipitated on an outer surface of the matrix material containing the composite oxide, and inner metal particles precipitated on an inner surface of the matrix material containing the composite oxide.

Abstract: A method of producing a H2 rich gas stream includes supplying an O2 rich gas, steam, and fuel to an inner reforming zone of a fuel processor that includes a partial oxidation catalyst and a steam reforming catalyst or a combined partial oxidation and stream reforming catalyst. The method also includes contacting the O2 rich gas, steam, and fuel with the partial oxidation catalyst and the steam reforming catalyst or the combined partial oxidation and stream reforming catalyst in the inner reforming zone to generate a hot reformate stream. The method still further includes cooling the hot reformate stream in a cooling zone to produce a cooled reformate stream. Additionally, the method includes removing sulfur-containing compounds from the cooled reformate stream by contacting the cooled reformate stream with a sulfur removal agent.

Abstract: Method and apparatus for steam reforming a sulfur-containing hydrocarbon fuel, such as a diesel hydrocarbon fuel. The apparatus includes a desulphurization unit, a pre-reformer, and a steam reforming unit. A carbon dioxide fixing material is present in the steam reforming catalyst bed to fix carbon dioxide that is produced by the reforming reaction. The carbon dioxide fixing material is an alkaline earth oxide, a doped alkaline earth oxide or a mixture thereof. The fixing of carbon dioxide within the steam reforming catalyst bed creates an equilibrium shift in the steam reforming reaction to produce more hydrogen and less carbon monoxide. Carbon dioxide fixed in the catalyst bed can be released by heating the carbon dioxide fixing material or catalyst bed to a temperature in excess of the steam reforming temperature. Fuel processors having multiple catalyst beds and methods and apparatus for generating electricity utilizing such fuel processors in conjunction with a fuel cell are also disclosed.

Abstract: A hydrogen generation apparatus includes controls for delivering a feedstock to a reactor and a water gas step membrane reactor operating at a lower temperature than the reactor so as to efficiently produce purified hydrogen and manage heat within the apparatus. Catalytic combustion of feedstock in the presence of a combustible gas based on a computer controller facilitates operation. Flat plate heat exchangers in various configurations are contemplated as a reactor, water gas step membrane reactor, and purifier. Catalytic burning of feedstock in the presence of a combustible gas enhances apparatus efficiency.

Abstract: A hydrogen-rich reformate gas generator, such as a mini-CPO (catalytic partial oxidizer) (36), provides warm, dry, hydrogen-containing reformate gas to a hydrogen desulfurizer (17) which provides desulfurized reformate gas to a major reformer (14) (such as a CPO) which, after processing in a water-gas shift reactor (26) and preferential CO oxidizer (27) produces hydrogen-containing reformate in a line (31) for use, for instance, as fuel for a fuel cell power plant. The expensive prior art hydrogen blower (30) is thereby eliminated, thus reducing parasitic power losses in the power plant. The drier reformate provided by the mini-CPO to the hydrogen desulfurizer favors hydrogen sulfide adsorption on zinc oxide and helps to reduce sulfur to the parts per billion level.

Abstract: A gas mixture 2 containing a fuel, water and air is supplied to one end of a reforming room 6, and a reformed gas 4 containing hydrogen is discharged from the other end thereof. Two or more such reforming units are connected in series, and the upstream part of each reforming room is filled with a first catalyst 8a which catalyzes a partial oxidation reaction in an oxygen-rich environment, and the downstream part is filled with a second catalyst 8b which performs the reforming reaction. The gas mixture 102 which has been heated in a heating unit 104 passes through a distribution tube 108 and is distributed evenly to the reforming units 114. The reforming room is composed of a reforming tube 130 in which a reforming catalyst 112 is charged, or two or more such reforming tubes, parallel to each other. After being reformed the high-temperature reformed gas 118 is passed around the reforming tubes, and fed back to a manifold 116.

Abstract: A hydrogen-rich reformate gas generator (36), such as a mini-CPO, POX, ATR or other hydrogen generator provides warm, dry, hydrogen-rich reformate gas to a hydrogen desulfurizer (17) which provides desulfurized feedstock gas to a major reformer (14) (such as a CPO) which, after processing in a water-gas shift reactor (26) and preferential CO oxidizer (27) produces hydrogen-containing reformate in a line (31) for use, for instance, as fuel for a fuel cell power plant. The expensive prior art hydrogen blower (30) is thereby eliminated, thus reducing parasitic power losses in the power plant. The drier reformate provided by the small hydrogen generator to the hydrogen desulfurizer favors hydrogen sulfide adsorption on zinc oxide and helps to reduce sulfur to the parts per billion level.

Abstract: A heat exchanger 32 comprises a first heat exchanger 40 for allowing heat to be exchanged between water and a reformed gas from a reforming reactor, a second heat exchanger 50 for spraying and vaporizing water in the reformed gas from the first heat exchanger 40, and a third heat exchanger 60 for vaporizing unvaporized or precipitated water. The reformed gas from the reforming reactor is cooled by the heating and vaporizing of water, and is mixed with the vaporized water and fed as mixed gas to a water gas shift reactor. The processes of cooling the reformed gas, heating and vaporizing of the water, and mixing the reformed gas and steam are completed in the heat exchanger 32, making it possible to design a smaller, simpler, and more efficient apparatus.

Abstract: A primary reactor for a fuel processor system that employs steam and air to convert a liquid hydrocarbon fuel into a hydrogen-rich gas stream. The liquid fuel and an air-steam mixture are mixed in a mixing region within the reactor. The fuel mixture is then directed through an electrically heated catalyst region that heats the mixture to the operation temperature of a light-off catalyst at system start-up. The heated fuel mixture is then directed through a light-off catalyst monolith where the hydrocarbon fuel is dissociated. Once the fuel mixture is heated to the operating temperature of the light-off catalyst, the electrically heated catalyst region is turned off because the exothermic reaction in the light-off catalyst monolith generates the heat necessary to sustain the catalytic reaction.

Abstract: A preferential oxidation reactor (PrOx) is provided including a plurality of substrates defining a plurality of channels, through which a reformate stream flows. A CO-sorption layer and a CO-catalyst layer coat a surface of each substrate support member. The PrOx operates in a first mode, generally at a temperature below 100° C., whereby the CO-sorption material adsorbs CO from the reformate stream. After operation in the first mode, the PrOx operates in a second mode, generally at a temperature above 100° C., whereby the CO-catalyst material enables a preferential oxidation reaction of CO in the reformate stream with a supply of oxygen and desorption of the CO previously absorbed by the CO-sorption layer for an overall reduction in the CO content of the reformate stream.

Abstract: Hydrogen and carbon are produced by decomposing natural gas or methane in a field of barrier discharge non-thermal plasma The apparatus for carrying out this process has two concentric elongated electrodes, one internal and one external, and a dielectric barrier between them, so arranged that there is a suitable gap between the internal electrode and the barrier. A high voltage pulser is connected to the electrodes and, when powered, creates the barrier discharge non-thermal plasma in the gas passing through the gap, thus decomposition this gas into its components, namely hydrogen and carbon.

Abstract: A chemical reaction apparatus includes a solid body which has an outer surface, and in which at least one flow path which allows a chemical medium to flow is formed. This body has a heating element which heats the chemical medium in the flow path to accelerate a chemical reaction of the chemical medium, and a heat radiation preventing film which covers at least a portion of the outer surface of the body, and prevents radiation of heat generated by the heating element from a portion of the outer surface.

Abstract: A chemical reaction apparatus includes a solid body in which a reaction flow path is formed, and a heater having a thin-film heater formed on the body to oppose the reaction flow path and at least partially exposed to the reaction flow path, and which supplies a predetermined heat amount to the reaction flow path by the thin-film heater.

Abstract: A system for generating hydrogen gas utilizes a volume exchange housing for the storage of a fuel material that reacts to generate hydrogen gas and a hydrogen separation chamber. The system includes a gas permeable membrane or membranes that allow hydrogen gas to pass through the membrane while preventing aqueous solutions from passing therethrough. The system is orientation independent. A throttle valve is also used to self regulate the reaction generating the hydrogen gas.

Abstract: Hydrogen-rich reformed gas is produced by reaction including partial oxidation of feed gas in a reforming reaction section (6). In this case, for the purpose of reducing temperature variations in the reforming reaction section (6), improving the thermal efficiency thereof and providing a reformer (A) with a simple and compact construction, the reformer (A) is formed in a double-wall structure consisting of a housing (1) and partitions (2), (2) inside of the housing (1), the reforming reaction section (6) is contained between the partitions (2), (2), and a feed gas passage (3) is provided by the space between the housing (1) and the partition (2). In this manner, the feed gas passage (3) is provided in the surrounding area of the reforming reaction section (6). The reforming reaction section (6) is thermally insulated by the feed gas passage (3) so that temperature variations in the reforming reaction section (6) can be reduced.

Abstract: A partial oxidation fuel reformer in includes a torch assembly for generating a near-stoichiometric flame through which a relatively rich “primary” air/fuel mixture is advanced. The torch assembly includes a low-energy ignition source such as a conventional sparkplug. The flame has sufficient energy to ignite the primary mixture to facilitate a partial oxidation reaction. A method of operating a partial oxidation fuel reformer is also disclosed.

Abstract: A cylindrical steam reforming unit comprising a plurality of cylindrical bodies consisting of a first cylindrical body, a second cylindrical body and a third cylindrical body of successively increasing diameters disposed in a concentric spaced relation, a radiation cylinder disposed within and concentrically with the first cylindrical body, a burner disposed in the radial central portion of the radiation cylinder, and a reforming catalyst layer with a reforming catalyst filled in a gap between the first and second cylindrical bodies, wherein a CO shift catalyst layer and a CO removal catalyst layer are disposed in a gap between the second and third cylindrical bodies, the CO shift catalyst layer being formed in a gap with the direction of flow reversed at one axial end of the reforming catalyst layer and through a heat recovery layer of predetermined length.

Abstract: A fuel reforming apparatus quickly heats the temperature of a catalyst to an activation temperature to shorten a startup time. The apparatus supplies a hydrocarbon fuel and an oxidizer upstream from a second catalyst (2), and steam upstream from a first catalyst (1). The second catalyst starts a rapid oxidation reaction to generate a high-temperature gas which heats the first catalyst. When the apparatus changes a startup operation or an accelerating operation to a steady operation after a predetermined period, the apparatus supplies the hydrocarbon fuel and steam upstream from the second catalyst, and the oxidizer upstream from the first catalyst. As a result, the second catalyst starts a steam reforming reaction to absorb heat from the second catalyst. And the second catalyst rapidly cools to stop reactions and pass the hydrocarbon fuel and steam with out reactions. Then, a hydrogen-rich reformed gas is generated from the passed hydrocarbon fuel and steam.

Abstract: The present invention is an apparatus arranged to maximize heat utilization for a hydrocarbon steam reforming process to produce synthesis gas. The apparatus comprises a refractory lined vessel with partition walls that divide the inside of the vessel into (1) a combustion chamber(s) containing one or more burners, and (2) convection chambers used as a means to remove combustion products from the combustion chamber through one or more openings at the opposite end of the burner end. The combustion chamber contains one or more reformer tubes in which a mixed-feed of hydrocarbon and steam flow co-current with combustion products and receive direct radiant heat from the combustion flame through the tube wall. The convection chambers contain a tube-in-tube device filled with catalyst in the annuli.

Abstract: A compact, multitube steam reformer converts a fuel into a reformate stream comprising hydrogen. In one embodiment, the reformer comprises a closed vessel and a burner disposed within the vessel. The burner comprises a start fuel manifold for receiving and distributing a start fuel stream, an oxidant manifold for receiving and distributing an oxidant stream, and a burner fuel manifold for receiving and distributing a burner fuel stream. The oxidant manifold comprises a plurality of oxidant distribution tubes, each having an inlet end and an outlet end, disposed in a separator member. The burner fuel manifold comprises a plurality of burner fuel distribution tubes, each having an inlet end and an outlet end. The burner fuel distribution tubes extend through the start fuel manifold and the oxidant manifold and are fluidly isolated therefrom.

Abstract: A fuel conversion reactor includes a shell-and-tube heat exchanger for controlling the temperature of a hot gaseous mixture produced by catalytic or non-catalytic reaction of a fuel with a gaseous fluid, and for controlling the temperature of the gaseous fluid and/or the fuel prior to the reaction. The reactor is either a catalytic or non-catalytic burner, or a fuel reformer for converting a fuel to hydrogen. A preferred reactor includes an outer shell having first and second ends and an inner surface, a primary inner shell extending into the outer shell, the primary inner shell defining a heat exchanging chamber and having primary and secondary ends, and a secondary inner shell having a first end located adjacent the secondary end of the primary inner shell. One or more outlet apertures are formed between the two inner shells for passage of the gaseous fluid out of the heat exchanging chamber.

Abstract: A reaction state at an upstream portion of the catalyst unit in which a partial oxidation reaction occurs is detected by a first reaction state detector, and a reforming reaction state in the whole of the catalyst unit composed of a catalyst for promoting a steam reforming reaction and a catalyst for promoting a partial oxidation reaction is detected by a second reaction state detector. Based on a reaction state detected by the second reaction state detector, a first corrector corrects feed amounts of raw fuel gas and oxidation gas, which are supplied to the catalyst unit, and a second corrector corrects a feed amount of the oxidation gas supplied to the catalyst unit and/or a feed timing thereof, based on the reaction state detected by the first reaction state detector.

Abstract: A device and method for separating water into hydrogen and oxygen is disclosed. A first substantially gas impervious solid electron-conducting membrane for selectively passing protons or hydrogen is provided and spaced from a second substantially gas impervious solid electron-conducting membrane for selectively passing oxygen. When steam is passed between the two membranes at dissociation temperatures the hydrogen from the dissociation of steam selectively and continuously passes through the first membrane and oxygen selectively and continuously passes through the second membrane, thereby continuously driving the dissociation of steam producing hydrogen and oxygen. The oxygen is thereafter reacted with methane to produce syngas which optimally may be reacted in a water gas shift reaction to produce CO2 and H2.

Abstract: A synthetic gas manufacturing plant includes a reformer having a reaction tube, a combustion radiation unit arranged around the reaction tube to heat the reaction tube, and a convection unit communicating with the combustion radiation unit, a source gas supply passageway to supply a natural gas to the reformer, a steam supply passageway to supply steam to the source gas supply passageway, a carbon dioxide recovery apparatus to which a total amount of combustion exhaust gas flowing through the convection unit of the reformer is supplied, and which recovers carbon dioxide from the combustion exhaust gas, a compressor to compress the recovered carbon dioxide, and a return passageway to supply part or the whole of the compressed carbon dioxide from the compressor to the source gas supply passageway.

Abstract: A reactor vessel for the catalytic reforming of air and steam-fuel mix into a hydrogen rich output gas is designed to relevant pressure code requirements. The steam-fuel mix and/or air provided to the vessel may be internally pre-heated prior to contacting the catalyst. Reformate is selectively directed into a recuperator to accomplish such heating. A bypass valve to divert reformate around the recuperator is also provided to allow control of the reaction conditions. Notably, this control may be performed manually or by way of an automated system. The resulting vessel enhances the safety and performance of the vessel, and it is more easily integrated into a complete fuel processor system. A method for achieving these goals is also described.

Abstract: The invention relates to a gas generator, especially for generating treatment gas containing CO and H2, for heat treating metallic material at high temperatures. Said gas generator comprises at least one catalytic retort and has means for heating at least partial areas of the catalytic retort(s). According to the invention, the catalytic retort is divided into at least two retort areas (1, 2a, 2b, 2e) and at least one of the retort areas (1), preferably the retort area (1) located first in the direction of flow-through, is configured so that it can be removed from the gas generator.

Abstract: A hydrogen generating apparatus having a fuel feeding part, a water feeding part for fuel reforming, an oxidant gas feeding part, a reforming catalyst body, a heating part for the reforming catalyst, a CO shifting catalyst body and a CO purification catalyst body is provided wherein the reforming catalyst body, the CO shifting catalyst body and the CO purification catalyst body are sequentially ordered from the fuel feeding part toward the downstream side, and wherein a shifting catalyst of the shifting catalyst body contains as one component at least a platinum group-type catalyst.

Abstract: A micro component steam reformer system for producing hydrogen-enriched gas to power a fuel cell adapted for scalable power requirements. The steam reformer system uses a cycle in which, in laminar flow modules, a vaporized hydrocarbon is mixed with fuel cell off gas having a hydrogen component and combusted to heat vaporizers and a steam reformer. Vaporized hydrocarbons and water vapor are introduced as a feed stock into the steam reformer to produce a syn-gas, which is cooled and purified. The resulting principally hydrogen gas may be introduced into a hydrogen fuel cell. Off gas from the fuel cell is recycled to provide hydrogen and water for use in the system cycle.

Abstract: A process for producing a high temperature COx-lean product gas from a high temperature COx-containing feed gas, includes: providing a sorption enhanced reactor containing a first adsorbent, a shift catalyst and a second adsorbent; feeding into the reactor a feed gas containing H2, H2O, CO and CO2; contacting the feed gas with the first adsorbent to provide a CO2 depleted feed gas; contacting the CO2 depleted feed gas with the shift catalyst to form a product mixture comprising CO2 and H2; and contacting the product mixture with a mixture of second adsorbent and shift catalyst to produce the product gas, which contains at least 50 vol. % H2, and less than 5 combined vol. % of CO2 and CO. The adsorbent is a high temperature adsorbent for a Sorption Enhanced Reaction process, such as K2CO3 promoted hydrotalcites, modified double-layered hydroxides, spinels, modified spinels, and magnesium oxides.

Abstract: An apparatus and method to create a substantially pure hydrogen product stream before any subsequent purification steps. The apparatus provides a generally enclosed reaction vessel so as to reduce any extraneous exhaust materials from escaping. In addition, the apparatus includes a primary and a secondary reaction chamber which are generally held at equivalent or equal pressures while at substantially different temperatures. In addition, a reaction aid or cooperator is used to increase the production of the hydrogen product stream and to also increase the purity of the hydrogen product stream. The method includes using a two chamber apparatus along with the reaction cooperator to increase the hydrogen production and purity and recycling the reaction cooperator.

Abstract: The invention relates to a system for converting fuel and air into reformate with a reformer (10) which has a reaction space (12), a nozzle (14) for supplying a fuel/air mixture to the reaction space (12), and a fuel feed (16) for supplying fuel to the nozzle (14). As claimed in the invention it is provided that in the air inlet area (18) of the nozzle (14) there are air guidance means (40) which impart a swirl to the inflowing air.

Abstract: There is provided a reforming apparatus which shows high efficiency and excellent operation-starting performance, in spite of its compact body and simple structure.

Abstract: Process and apparatus for the preparation of synthesis gas by catalytic steam and/or CO2 reforming of a hydrocarbon feedstock comprising the following steps:

Abstract: A reforming and hydrogen purification system operating with minimal pressure drop for producing free hydrogen from different hydrogen rich fuels includes a hydrogen reforming catalyst bed in a vessel in communication with a core unit containing a hydrogen permeable selective membrane. The vessel is located within an insulated enclosure which forms an air inlet passageway and an exhaust passageway on opposite sides of the vessel. Air and raffinate pass through a burner within the air inlet passageway, providing a heated flue gas to heat the catalyst to the reaction temperature needed to generate free hydrogen from the feedstock. The burner flue gas flows laterally over and along the length of the bed between the input and output ends of the bed. Hydrogen is recovered from the core for use by a hydrogen-consuming device such as a fuel cell. The remaining unrecovered hydrogen in the reformed gases is contained in raffinate and is used to supply process heat via the burner.

Abstract: Process and apparatus for the preparation of synthesis gas by catalytic steam and/or CO2 reforming of a hydrocarbon feedstock comprising the following steps:

Abstract: A compact steam reformer produces hydrogen to power a fuel cell, such as can be used in a vehicle. The steam reformer includes a first channel, at least partly coated with a steam reforming catalyst, and a second channel, at least partly coated with a combustion catalyst, the channels being in thermal contact with each other. Heat from the combustion is used in the steam reforming reaction. The steam reformer may be provided as a stack of strips defining steam reforming channels which alternate with combustion channels. The reformer may also include a set of modules, connected in series, each module including a stack of strips as described above. The steam reformer preferably also includes a channel wherein a water-gas shift reaction occurs, to convert carbon monoxide, produced by the reformer, into carbon dioxide.

Abstract: In an integrated process for the production of synthesis gas, a partial oxidation unit (1) and a steam methane reformer (2) are used to convert natural gas or another fuel to first and second mixtures (11, 12) of at least carbon monoxide and hydrogen, only the first process consuming oxygen. Carbon dioxide (15, 25) derived from the second mixture is sent to the inlet of the first process to reduce the oxygen consumption.

Abstract: A fuel cell power plant (110) has a fuel cell stack assembly (CSA) (16) including an anode (18), and a fuel processing system (FPS) (120) providing a hydrogen-rich reformate/fuel stream (34, 134, 62) for the anode (18) of the CSA (16). A relatively active metal catalyst is associated with one or both of the anode (18) and the FPS (120), and is subject to degradation by the presence of even low levels, e.g. 100 ppb to 5 ppb-wt. reformate, of sulfur in the fuel stream. A guard bed (70) containing a guard material (72) is provided in the FPS (120) for protecting the relatively active metal catalysts by adsorbing, and further reducing the level of, sulfur in the fuel stream. The guard material (72) is a metal or metal oxide capable of forming a stable sulfide in the presence of low levels of H2S in the fuel stream (34), and is preferably selected from the group consisting of: ZnO, CuO on CeO2-based support, NiO on CeO2-based support, and Cu/ZnO.

Abstract: The composition of moisturized fuel gas exiting a fuel gas saturator is controlled using feed forward control. The level of the water is manipulated by adjusting the valve that controls the make-up water. The level controller uses the moisture content of moisturized fuel gas, the flow rate of the dry fuel gas entering the fuel gas saturator, the level of the water at the bottom of the fuel gas saturator and the flow rate of the make-up water to control the valve. Moisture content of the moisturized fuel gas and the flow rate of the dry gas entering the fuel gas saturator are used to calculate the flow rate of water leaving with the moisturized fuel gas. Error is minimized in determination of the flow rate of water leaving with the moisturized fuel gas, thereby allowing tighter control over the process unit.

Abstract: An apparatus removes CO from a hydrogen-rich gas stream in a hydrogen fuel cell system. CO fouls costly catalytic particles in the membrane electrode assemblies. Both a catalyst adapted to perform a water gas shift reaction, and a carbon dioxide adsorbent are disposed in a rotating pressure swing adsorber housing. The adsorption of carbon dioxide shifts equilibrium toward carbon monoxide consumption. A second adsorbent may be disposed in the housing for adsorbing carbon monoxide at low temperatures, and is adapted to desorb carbon monoxide at high temperatures. The present invention advantageously eliminates a unit operation from a space-constrained fuel cell vehicle by combining the WGS catalyst and a CO2 adsorbent in a single reactor/housing. The apparatus further eliminates the use of a PROX reactor, by providing an apparatus which incorporates CO2 adsorption and consequent carbon monoxide consumption in the place of the PROX reactor.

Abstract: A compact steam reformer produces hydrogen to power a fuel cell, such as can be used in a vehicle. The steam reformer includes a first channel, at least partly coated with a steam reforming catalyst, and a second channel, at least partly coated with a combustion catalyst, the channels being in thermal contact with each other. Heat from the combustion is used in the steam reforming reaction. In another embodiment, the gas streams feeding the reforming and combustion channels pass through a valve which reverses the gas streams periodically. The combustion channel becomes the reforming channel, and vice versa, so that carbon deposits in the former reforming channel are burned off. This arrangement enables the reforming reaction to continue indefinitely at peak efficiency.

Abstract: A method is provided for maintaining low concentration of carbon monoxide in a fuel processor product hydrogen stream during transient operation with a residential fuel cell, particularly during increases in load demand (turn-up). Algorithms have been developed for controlling the air flow to a preferential oxidation reactor and for controlling the rate of direct water injection for rapid steam generation in a water gas shift reactor.