Abstract: The concentration of carbon monoxide in a gaseous medium is reduced by selective catalytic oxidation in the presence of gaseous oxygen by passing the gaseous medium through a catalyst capable of oxidizing carbon monoxide in an exothermic reaction at temperatures within a given temperature range and by controlling the temperatures encountered in the catalyst in such a manner that the exothermic reaction takes place first above a threshold temperature below which the catalyst would be rapidly inactivated at the relatively high carbon monoxide concentrations present in the gaseous medium as it enters the catalyst, and subsequently, after the carbon monoxide concentration has been reduced to an acceptable level, at less than the threshold temperature to further reduce the carbon monoxide concentration to a desired minimum level below that achievable at temperatures above the threshold temperature.

Abstract: The gas stream which is produced in and emanates from landfills, anaerobic digesters and other waste gas streams, is treated to produce a purified gas which is essentially a hydrocarbon such as methane and which can be used as the fuel source in a fuel cell power plant. The gas stream passes through a simplified purification system which removes essentially all of the sulfur compounds, hydrogen sulfide, and halogen compounds from the gas stream. The resultant gas stream can be used to power a fuel cell power plant which produces electricity, or as a hydrocarbon fuel gas for other applications.

Abstract: Sulfur and sulfur compounds are removed from a gas stream, such as a hydrocarbon fuel gas stream so as to render the gas stream suitable for use in a fuel cell power plant. Natural gas and recycled hydrogen enters the hydrodesulfurizer assembly at a temperature of about 120.degree. F. The gas stream is heated to a temperature of about 625.degree. F. whereupon it enters a desulfurizing bed formed from a mixture of platinum catalyst deposited on alumina pellets, and a pelletized zinc oxide hydrogen sulfide absorbent. The gas is cooled to an exit temperature of about 525.degree.F. as it passes through the desulfurizer bed. The desulfurizer bed is combined with a shift converter which reduces carbon monoxide in the desulfurized gas stream after the latter has passed through a steam reformer bed.

Abstract: A fuel gas reformer assemblage for use in a fuel cell power plant is formed from a composite plate assembly which includes spaced-apart divider plates with interposed columns of individual gas passages. The reformer assemblage is constructed from a series of repeating sub-assemblies, each of which includes a core of separate regenerator/heat exchanger gas passages. The core in each sub-assembly is sandwiched between a pair of reformer gas passage skins, which complete the sub-assembly. Adjacent reformer gas/regenerator/reformer gas passage sub-assemblies in the composite plate assembly are separated from each other by burner gas passages. The regenerator/heat exchanger gas passages and the reformer gas passages in each sub-assembly are connected by gas flow return manifolds which form a part of each sub-assembly.

Abstract: A proton exchange membrane fuel cell device with an internal water management and transfer system includes a plurality of adjacently arranged proton exchange membrane assemblies including a proton exchange membrane component; a pair of porous anode and cathode catalyst layers situated on either side of the proton exchange membrane; and porous plate assemblies interposed between and in contact with each of the adjacent proton exchange membrane assemblies. Oxidant gas is supplied to oxidant gas supply channels, and fuel gas to fuel gas supply channels formed in the porous plate assemblies for distribution to the cathode and anode catalyst layers, respectively. A water coolant circulating system is formed in each of the porous plate assemblies and causes each of the porous plate assemblies to become saturated with coolant water. The reactant flow fields are pressurized to a pressure which exceeds the coolant water circulating pressure by a selected .DELTA.

Abstract: A polymer electrolyte membrane fuel cell includes an anode chamber and a cathode chamber which are separated by the electrolyte membrane. The fuel cell directly oxidizes a liquid methanol fuel which is fed into the anode chamber from a liquid methanol storage container. The liquid methanol is mixed with water in the anode chamber, and the mixture passes into and through the electrolyte membrane. Some of the methanol and water pass through the membrane into the cathode chamber and into a process air stream which moves through the cathode chamber. The methanol and water are removed from the cathode chamber by evaporation into the process air stream, which then is directed into a condenser/radiator. The methanol and water vapors are condensed in the condenser/radiator, from whence the condensed water and methanol are returned to the anode chamber of the cell. The evaporating cathode process air stream provides oxygen for the fuel cell reaction, and also cools the cell.

Abstract: The cell stack assembly of a fuel cell power plant is provided with a cooling system which provides optimum cell operating temperatures across each cell in the stack and also produces an optimum amount of steam. The cooling system includes at least one bypass through which a fraction of the coolant is fed from the coolant inlet side of the stack to the coolant outlet side of the stack. The bypass ensures that a fraction of the coolant is not heated to its target operating temperatures as it passes through the stack. This results in a more uniform cell operating temperature profile from the coolant inlet to the coolant outlet side of each cell; and also results in a lessening of excess steam production in the power plant.

Abstract: A simplified solid polymer electrolyte fuel cell power plant utilizes porous conductive separator plates having central passages which are filled with circulating coolant water. The coolant water passes through a heat exchanger which rejects heat generated in the power plant. Water appearing on the cathode side of each cell membrane is pumped into the water circulation passages through the porous oxidant reactant flow field plates by a positive .DELTA.P created between the cathode reactant flow field of each cell and the coolant water circulation passages between each cell. In order to create the desired .DELTA.P, at least one of the reactant gas streams will be referenced to the coolant water loop so as to create a coolant loop pressure which is less than the referenced reactant gas stream pressure. Excess water is removed from the coolant water stream. The system can operate at ambient or at elevated pressures.

Abstract: A molten carbonate fuel cell power plant is disclosed. The power plant of the present invention includes an insulated enclosure and a fuel cell stack, a sensible heat reformer, fuel stream and air stream recycle loops and a catalytic burner, each within the enclosure. The molten carbonate fuel cell power plant of the present invention is compact, easily transportable and provides cost and efficiency improvements over conventional molten carbonate fuel cell power plants.

Abstract: A continuous, pinhole-free thermoplastic polymer coating, which may be a fluoroelastomer, is applied to a porous metal surface in a single coating step by spraying the thermoplastic polymer from a thermal spray gun onto a porous metal surface which is at substantially room temperature to form a semi-fused, highly porous coating. The porous metal surface is then heated to fuse the thermoplastic polymer coating into a well-anchored, continuous film. This method permits the application of a continuous thermoplastic polymer coating with one coating step rather than with the plurality of coating steps currently needed to produce a coating with comparable properties.

Abstract: A seal structure 58 between adjacent porous plates 18, 20 and a method of making the seal structure for an electrochemical cell are disclosed. Various construction details are developed which facilitate fabrication and assembly. In one embodiment, the adjacent porous plates are electrolyte reservoir plates joined together at a three-layer seal structure to form an integral assembly.