Abstract: In an automated process for deaerating and purifying both the water which is recirculated in a coolant loop through a stack of fuel cells and the make-up water for the coolant loop, a portion of the water from the coolant loop is blown down into a deaerator water reservoir to which make-up water is added by condensing water from the fuel cell stack reactant gas streams into a deaeration column disposed above the reservoir. The blowdown provides some of the heat for deaeration; and the amount of blowdown is controlled as a function of the amount of make-up water added to the coolant loop by sensing the location of a steam/liquid interface within the deaeration column. Water is withdrawn from the reservoir, purified, and then introduced into the coolant loop at a rate sufficient to maintain the desired amount of water circulating in the coolant loop.

Abstract: To avoid using high quality heat to boil water condensed from a moist gas stream and to increase the overall thermal efficiency in a system requiring a supply of steam obtained by boiling water condensed from a moist gas stream, the condensing of the desired amount of water is done in a combined condenser/boiler wherein the condensed out water is separated from the gas stream, reduced in temperature, and throttled to a pressure wherein it is converted to steam back in the condenser/boiler using only the heat of condensation and sensible heat from the moist gas stream during the condensing step.

Abstract: Thru-cracks in the electrolyte retaining matrix of a molten carbonate fuel cell caused by thermal cycling of the cell between operating and room temperature are prevented by an improved matrix comprising a major proportion of submicron support particles and a minor proportion, perhaps only a few percent, of much larger crack attenuator particles. In one embodiment wherein the electrolyte is to be a binary lithium-potassium carbonates composition, the matrix comprises 90 volume percent submicron lithium aluminate support particles and 10 volume percent alumina crack attenuator particles with an average size of 100 microns.

Abstract: A method for making an electrochemical cell electrode involves depositing a layer of dry carbon/hydrophobic polymer powder on the surface of a substrate by dispersing the powder as a cloud in a chamber over the substrate and pulling the powder onto the substrate by drawing a vacuum under the substrate. The electrode is subsequently compacted and sintered. Typically the carbon component of the powder is catalyzed, such as with platinum. Thus, the method is for applying a catalyst layer on an electrode substrate. The method is particularly adapted to the high speed manufacture of electrodes.

Abstract: To improve cooling and simplify construction the cavity of a hollow airfoil is divided into separate longitudinally extending pressure and suction side compartments each of which extend from the leading edge to the trailing edge portion of the airfoil for providing cooling air to their respective sides of the airfoil. Air enters one compartment from one end of the airfoil and is closed at its opposite end. Air enters the other compartment from the end opposite the inlet end of the first compartment and is closed at its other end. In a preferred embodiment a tubular insert provides the dividing wall between the compartments and forms a plenum within the suction side compartment from which cooling air is directed against the suction-side wall through impingement cooling holes in the insert.

Abstract: A rotary atomization apparatus for making metal powders from liquid metals comprises an atomizer disk having a concave top surface for receiving a flow of molten metal thereon. The disk is preferably made from a high strength zirconium-containing copper base alloy. The disk is driven by a surrounding drive portion thru a radial spline-type connection. Higher rotational speeds than the prior art are the major advantage of this invention.

Abstract: Cathode sputtering apparatus for coating articles which are rotated within a vacuum sputtering chamber and which are electrically biased includes a shaft for supporting the articles to be coated, wherein the shaft is supported by a plurality of non-lubricated bearings disposed within the vacuum chamber, at least one of the bearings being designed to conduct electricity to the shaft, that bearing being a thrust bearing supported by and in electrical contact with a bearing support plate and having races and rolling elements preferably made from either molybdenum or tungsten which are very hard materials with low electrical resistivity.

Abstract: A thin electrochemical cell separator plate with greatly improved properties is made by molding and then graphitizing a mixture of preferably 50 percent high purity graphite powder and 50 percent carbonizable thermosetting phenolic resin, the graphite molding powder particles having a specified preferred shape and a size distribution requiring 31 to 62 weight percent of the particles to be less than 45 microns in size.

Abstract: A catalytic reaction vessel makes hydrogen from a hydrocarbon feedstock and steam using heat stored in the vessel, and the vessel is then regenerated to restore the heat. Regeneration is done by preheating, separately and within the vessel, an oxygen containing gas and a hydrogen purge gas, and mixing these preheated gases so that they combust within the vessel and heat material disposed in the vessel. This is the heat which is used in converting the hydrocarbon feedstock to hydrogen.

Abstract: To more uniformly distribute heat to the plurality of catalyst tubes in a catalytic reaction furnace, the burner disposed in the furnace above the tops of the tubes includes concentric primary and secondary annular fuel and air outlets. The fuel-air mixture from the primary outlet is directed towards the tubes adjacent the furnace wall, and the burning secondary fuel-air mixture is directed horizontally from the secondary outlet and a portion thereof is deflected downwardly by a slotted baffle toward the tubes in the center of the furnace while the remaining portion passes through the slotted baffle to another baffle disposed radially outwardly therefrom which deflects it downwardly in the vicinity of the tubes between those in the center and those near the wall of the furnace.

Abstract: A method for making an electrochemical cell electrode involves depositing a layer of dry carbon/hydrophobic polymer floc powder on the surface of a substrate by dispersing the powder as a cloud in a chamber over the substrate and pulling the powder onto the substrate by drawing a vacuum under the substrate. The electrode is subsequently compacted and sintered. Typically the carbon component of the floc is catalyzed, such as with platinum. Thus, the method is for applying a catalyst layer on an electrode substrate. The method is particularly adapted to the high speed manufacture of electrodes.

Abstract: In apparatus for producing metal powder by rapid solidification of molten metal particles flung into a quenching chamber from a rotating disk through vertical zones of cooling fluid, improved cooling fluid flow, improved operating efficiency and low pressure losses are provided by having the cooling fluid introduced into the quenching chamber via a plurality of cylindrical tubes each having an inlet within a coolant fluid manifold and an outlet opening into the quenching chamber. Each tube including means for creating a cooling fluid vortex flow therein which exits from the tube outlet into the quenching chamber as an expanding cone of swirling fluid. A plurality of these tubes are appropriately located around the rotating disk to create a desired pattern of cooling fluid flow around the disk and through which the molten metal particles will pass as they solidify into the powder.

Abstract: The object of the invention is to provide a process for vaporizing liquid hydrocarbon fuels efficiently and without the formation of carbon residue on the apparatus used.The process includes simultaneously passing the liquid fuel and an inert hot gas downwardly through a plurality of vertically spaed apart regions of high surface area packing material. The liquid thinly coats the packing surface, and the sensible heat of the hot gas vaporizes this coating of liquid. Unvaporized liquid passing through one region of packing is uniformly redistributed over the top surface of the next region until all fuel has been vaporized using only the sensible heat of the hot gas stream.

Abstract: A porous fuel cell component, such as an electrode substrate, has a densified edge which forms an improved gas seal during operation when soaked with electrolyte. The edges are made from the same composition as the rest of the component and are made by compressing an increased thickness of this material along the edges during the fabrication process.

Abstract: In fabricating sheet material with closely spaced parallel ribs on one side, a mold with ribbed shaped grooves is uniformly filled with a loose, dry molding material using a coater with a plurality of adjacent blades extending therefrom with the blade tips parallel to and preferably in contact with the mold top surface. The coater is swept across the mold top surface and the blades distribute and compress the molding material into the mold grooves. The invention is particularly useful for molding materials with high fiber content which are difficult to pack uniformly and with sufficient density into the mold.

Abstract: Ammonia gas is scrubbed from a gas stream in a bed of material soaked with acid, and the bed is regenerated by passing an oxygen containing gas therethrough. The preferred acid is phosphoric acid and the preferred support material is carbon in the form of porous particles. In a fuel cell system dual scrubbers alternately scrub ammonia from reform gas and are subsequently regenerated so as to provide the fuel cells with a continuous flow of substantially ammonia free hydrogen.

Abstract: A new type of electrochemical cell which can be used for generating electricity or in an electrolysis mode for producing gases such as hydrogen and oxygen comprises laterally spaced apart or side-by-side catalyst layers as electrodes with the gap between the catalyst layers being bridged by a solid electrolyte which provides an ion conductive path from one catalyst layer to the other. The catalyst layers and the electrolyte are preferably in the form of thin films or layers on the surface of an inert supporting substrate. A plurality of these cells may be disposed on the substrate and interconnected electrically forming a network of series and parallel connected cells. Means are provided to feed fuel and oxidant to the electrodes either as separate gases or mixed together if appropriate catalytic materials are selected.

Abstract: A coolant tube holder for a stack of fuel cells is a gas porous sheet of fibrous material adapted to be sandwiched between a cell electrode and a nonporous, gas impervious flat plate which separates adjacent cells. The porous holder has channels in one surface with coolant tubes disposed therein for carrying coolant through the stack. The gas impervious plate is preferably bonded to the opposite surface of the holder, and the channel depth is the full thickness of the holder.

Abstract: A process is disclosed for making hydrogen from a hydrocarbon feedstock and steam using heat stored in a vessel, and the vessel is then regenerated to restore the heat. Regeneration is done by preheating, separately and within the vessel, an oxygen containing gas and a hydrogen purge gas, and mixing these preheated gases so that they combust within the vessel and heat material disposed in the vessel. This is the heat which is used in converting the hydrocarbon feedstock to hydrogen.

Abstract: A cooler assembly for a stack of fuel cells comprises a fibrous, porous coolant tube holder sandwiched between and bonded to at least one of a pair of gas impervious graphite plates. The tubes are disposed in channels which pass through the holder. The channels are as deep as the holder thickness, which is substantially the same as the outer diameter of the tubes. Gas seals along the edges of the holder parallel to the direction of the channels are gas impervious graphite strips.