Abstract: A process for making dry carbon/polytetrafluoroethylene floc material, particularly useful in the manufacture of fuel cell electrodes, comprises of the steps of floccing a co-suspension of carbon particles and polytetrafluoroethylene particles, filtering excess liquids from the co-suspension, molding pellet shapes from the remaining wet floc solids without using significant pressure during the molding, drying the wet floc pellet shapes within the mold at temperatures no greater than about 150.degree. F., and removing the dry pellets from the mold.

Abstract: A porous graphite reservoir layer for retaining electrolyte within a fuel cell is improved by coating the pore surfaces of the reservoir layer with wettable, particulate amorphous carbon. Preferably the amorphous carbon particles are colloidal and have a mean pore size considerably smaller than the pore size of the body which they coat. This coated reservoir retains its hydrophilic properties for an extended period of time.

Abstract: Porous cathodes for molten carbonate type fuel cells are made from perovskites. The perovskites tested to date all appear to be good cathode catalysts for the reduction of oxygen in molten carbonate electrolyte and are also stable in the electrolyte.

Abstract: Fuel cell performance is degraded by recycling a portion of the cathode exhaust through the cells and, if necessary, also reducing the total air flow to the cells for the purpose of permitting operation below a power level which would otherwise result in excessive voltage.

Abstract: A hydrotreating catalyst is regenerated as it concurrently hydrotreats a hydrocarbon fuel by introducing a low concentration of oxygen into the catalyst bed either continuously or periodically. At low oxygen concentrations the carbon deposits on the catalyst are burned off without harming the catalyst and without significantly affecting the hydrotreating process. In a preferred embodiment the hydrotreating process is hydrodesulfurization, and regenerating is done periodically with oxygen concentrations between 0.1 and 0.5 volume percent.

Abstract: A novel catalyst comprises an alloy of a noble metal and vanadium. The catalyst is particularly useful in an electrochemical cell cathode electrode. The method for making the alloy involves reacting a vanadium compound with sodium dithionite to form a sol of a finely dispersed vanadium sulfite complex, and then reacting noble metal particles with the complex in a reducing environment.

Abstract: A pair of reaction vessels provide hydrogen to a fuel cell by making hydrogen in one of the vessels while simultaneously regenerating the other vessel, and then reversing the function of the vessels. In the vessel making hydrogen a hydrocarbon feedstock is cracked and steam reformed using sensible heat generated during the regeneration of the vessel. Regeneration includes preheating, separately within the reaction vessel, fuel cell fuel electrode exhaust and an oxygen containing gas. Preheating is accomplished using the heat of combustion and/or sensible heat stored within material disposed within the vessel while it is making hydrogen. After being preheated the fuel electrode exhaust and oxygen containing gas are allowed to mix and combust within the vessel, thereby heating materials disposed therein. This heat is the heat used to crack and steam reform the hydrocarbon fuel.

Abstract: A support system which enables a rain gutter to be inverted and emptied of debris includes a link pivoted at its rear end to a bracket attached to a building, and at its front end to the gutter. The gutter can pivot about the front end of the link to an inverted position. In its normal position the gutter rests on support arms extending outwardly from the building underneath the gutter. The support system is usable with all commercially available gutters.

Abstract: A novel and improved fuel cell electrode includes a finely divided noble metal-base metal alloy catalyst. The catalytic activity of noble metal in the electrode is greater than the catalytic activity of the same unalloyed noble metal. Theoretically any base metal may be advantageously alloyed with the noble metal and will yield improved catalytic activity. Preferably the finely divided alloy is supported.

Abstract: In a method for producing high quality hydrogen, the carbon monoxide level of a hydrogen stream which also contains hydrogen sulfide is shifted in a bed of iron oxide shift catalyst to a desired low level of carbon monoxide using less catalyst than the minimum amount of catalyst which would otherwise be required if there were no hydrogen sulfide in the gas stream. Under normal operating conditions the presence of even relatively small amounts of hydrogen sulfide can double the activity of the catalyst such that much less catalyst may be used to do the same job.

Abstract: Finely divided noble metal-refractory metal alloys and methods for making them are disclosed. As catalysts these alloys have greater activity than a catalyst of the same unalloyed noble metal and may be advantageously used as electrodes for fuel cells particularly when supported. The method for making supported catalysts involves a simple and inexpensive procedure for converting a supported, finely divided noble metal catalyst to the desired alloy. In a preferred embodiment the process includes intimately contacting the supported noble metal catalyst with a finely divided refractory metal oxide, the metallic component of which is capable of enhancing the activity of the catalyst when alloyed therewith, and then heating to a sufficiently high temperature, preferably in a reducing atmosphere, to reduce the oxide and simultaneously form a finely divided, supported alloy of the noble metal and the metallic component of the oxide.

Abstract: A porous graphite reservoir layer for retaining electrolyte within a fuel cell is improved by coating the pore surfaces of the reservoir layer with wettable, particulate amorphous carbon. Preferably the amorphous carbon particles are colloidal and have a mean pore size considerably smaller than the pore size of the body which they coat. This coated reservoir retains its hydrophilic properties for an extended period of time.

Abstract: Fuel cell electrodes of uniform quality are made on a continuous basis using screen printing. A wet floc is first made by floccing a co-suspension of carbon and hydrophobic polymer. The floc is dried, reduced to a fine powder, and re-suspended in an inking vehicle. The ink is then screen printed onto a porous substrate and the inking vehicle is removed such as by heating. The layer is compacted, sintered, and then catalyzed such as with platinum.

Abstract: In the hydrotreating and steam reforming of an oxygen and sulfur bearing hydrocarbon fuel the oxygen is first removed in an oxidizer containing a bed of platinum catalyst, the inlet temperature being well below 1000.degree. F. and preferably on the order of 300.degree. F. The sulfur in the fuel does not harm the oxidizer catalyst and may be removed downstream by known hydrodesulfurization techniques prior to reforming.

Abstract: A novel powder particularly suitable for forming the catalyst layer in the manufacture of electrochemical cell electrodes comprises a high molecular weight fluorocarbon polymer and precatalyzed carbon. The maximum size of the particles is about five microns and the polymer has a molecular weight of at least one million.

Abstract: A method for making an electrochemical cell electrode involves depositing a layer of mechanically blended dry catalyzed carbon powder and dry hydrophobic polymer powder on the surface of a substrate by dispersing the mixture of powders as a cloud in a chamber over the substrate and pulling the powder onto the substrate by drawing a vacuum under the substrate. The method is particularly adapted to the high speed manufacture of electrodes.

Abstract: A process for forming a fuel cell electrolyte matrix on the surface of an electrode involves passing the electrode through a vertically falling curtain or waterfall of the matrix material carried in a liquid vehicle. The coated electrode is then heat treated to remove the liquid vehicle, leaving a layer of matrix material on the electrode surface. This curtain coating process has been used to produce matrix layers of 2.5 mils having a variation in thickness of no more than 0.2 mils.

Abstract: An economical method for fabricating a porous electrochemical cell substrate having ribs on one side comprises molding the substrate by loading a die of the proper configuration with a predetermined amount of a dry mixture of thermosetting resin and carbon fibers. The mixture is partially cured using heat and low pressure and then is fully cured up to at least 1100.degree. C. to convert all the resin to glassy carbon. The amount of mixture loaded into the die is preselected to yield a finished part having a porosity of at least 75%. Preferably the ribbed substrate is wetproofed in all areas except the ribs which are used to store excess electrolyte during cell operation.

Abstract: Electrocatalyst and hydrophobic polymer particles are combined to form an aqueous suspension which is then applied to a conductive substrate to form an electrode. The colloidal chemistry of the suspension of electrocatalyst particles and hydrophobic polymer particles is controlled prior to the application of the suspension to the substrate such as by the incorporation of a sol of a polyvalent metal oxide or solution of a salt of a polyvalent metal into the suspension.

Abstract: A thermally conductive caulk particularly suited for use in a phosphoric acid fuel cell is made by mixing graphite into a stable aqueous dispersion of polytetrafluoroethylene and fluorinated ethylene propylene such that the solids floc to form a paste. The paste is applied to the part to be caulked and then dried and heat treated. Caulks made according to the present invention have good thermal conductivity and absorb very little phosphoric acid.