Abstract: A hydrogen purification device, components thereof, and fuel processors and fuel cell system containing the same. The hydrogen purification devices include an enclosure that contains a separation assembly adapted to receive a mixed gas stream containing hydrogen gas and to produce a stream that contains pure or at least substantially pure hydrogen gas therefrom. The separation assembly may include at least one hydrogen-permeable and/or hydrogen-selective membrane, In some embodiments, the enclosure includes a pair of end plates and a shell extending generally between the end plates. In some embodiments, the enclosure includes a shell that is integrated with at least one of the end plates. In some embodiments, at least one of the end plates includes a deflection and/or stress abatement structure. In some embodiments, the device includes components formed from materials having similar or the same coefficients of thermal expansion.

Abstract: A fuel cell system that includes a control system for regulating the power produced by the fuel cell system. The fuel cell system includes a fuel cell stack adapted to produce electrical power from a feed. In some embodiments, the fuel cell system includes a fuel processing assembly adapted to produce the feed for the fuel cell stack from one or more feedstocks. The control system regulates the power produced by the fuel cell system to prevent damage to, and/or failure of, the system.

Abstract: A system and method for recovering thermal energy from a fuel processing system comprising a fuel processor and a fuel cell stack. The system includes a heat recovery system including a heat exchange fluid that recovers thermal energy from such sources as the combustion exhaust from the fuel processor, the cathode chamber exhaust from the fuel cell stack and/or the fuel cell stack directly.

Abstract: Membrane modules that contain one or more hydrogen-selective membranes, methods for preparing the same, and hydrogen purification systems, fuel processors and devices containing the same. In some embodiments, the membrane modules include one or more hydrogen-selective membranes supported on a screen structure, of which a variety of embodiments are disclosed. In some embodiments, the membrane or membranes are adhesively mounted on the screen structure during assembly. In some embodiments, the screen structure includes a plurality of screen members adhesively mounted together during assembly. In some embodiments, the screen structure includes a coating.

Abstract: A system and method for preventing damage to a fuel cell stack resulting from impurities in the product stream from a fuel processor, such as may occur should the separation region of the fuel processor fail. The system and method include detecting the concentration of at least one component of the product stream and isolating the fuel cell stack should this concentration exceed an acceptable threshold level. Examples of impurities in the product stream include; carbon monoxide, carbon dioxide, methane and water.

Abstract: A hydrogen-permeable metal membrane with increased hydrogen flux compared to conventional metal membranes is disclosed. Without sacrificing selectivity, the membrane enables a greater throughput of purified hydrogen. A method for preparing the invention includes at least one etching step in which a controlled volume of etchant is used to selectively remove material from the membrane's surface. Methods for repairing holes or other defects in the membrane are also disclosed.

Abstract: A control system and method for a fuel processing system. The control system automates the operation of a fuel processing system by monitoring operating parameters and automatically controlling the operation of the system responsive to the monitored parameters, predefined subroutines and/or user inputs.

Abstract: A fuel processing assembly adapted to produce hydrogen gas from a carbon-containing feedstock. The fuel processing assembly includes a fuel processor, such as a steam reformer. The fuel processing assembly further includes a feed assembly adapted to deliver a carbon-containing feedstock, such as a hydrocarbon, to the fuel processor. In some embodiments, the fuel processing system includes a fuel cell stack that includes at least one fuel cell adapted to produce electrical power from hydrogen gas produced by the fuel processor.

Abstract: The invented system includes a fuel-cell system comprising a fuel cell that produces electrical power from air (oxygen) and hydrogen, and a fuel processor that produces hydrogen from a variety of feedstocks. One such fuel processor is a steam reformer which produces purified hydrogen from a carbon-containing feedstock and water. In the invented system, various mechanisms for implementing the cold start-up of the fuel processor are disclosed, as well as mechanisms for optimizing and/or harvesting the heat and water requirements of the system, and maintaining desired the feed ratios of feedstock to water in the fuel processor and purity of the process water used in the system.

Abstract: Membrane modules that contain one or more hydrogen-selective membranes, methods for preparing the same, and hydrogen purification systems, fuel processors and devices containing the same. In some embodiments, the membrane modules include one or more hydrogen-selective membranes supported on a screen structure, of which a variety of embodiments are disclosed. In some embodiments, the membrane or membranes are adhesively mounted on the screen structure during assembly. In some embodiments, the screen structure includes a plurality of screen members adhesively mounted together during assembly. In some embodiments, the screen structure includes a coating.

Abstract: A system for optimizing the purge cycle of a fuel cell stack responsive to the performance of the fuel cell. The system includes a controller that measures a process parameter indicative of the rate at which water is being produced in the fuel cell. If the measured value exceeds a threshold value, then the purge assembly is automatically actuated.

Abstract: A fuel processing system is disclosed. The system includes a steam reformer adapted to produce hydrogen from a feedstock consisting of water and at least one of an alcohol and a hydrocarbon feedstock. The hydrogen is produced by reacting the feedstock in the present of a reforming catalyst. The product stream is passed through a hydrogen-selective membrane module, at which the permeate stream is polished to remove trade carbon monoxide and carbon dioxide, and the byproduct stream is combusted to heat the reformer.

Abstract: A hydrogen-permeable metal membrane with increased hydrogen flux compared to conventional metal membranes is disclosed. Without sacrificing selectivity, the membrane enables a greater throughput of purified hydrogen. A method for preparing the invention includes at least one etching step in which a controlled volume of etchant is used to selectively remove material from the membrane's surface. Methods for repairing holes or other defects in the membrane are also disclosed.