Abstract: Methods of using a catalyst preburner upstream of a catalyst burner, such as an anode tailgas oxidizer (ATO), in fuel processing applications. The methods prepare a hydrogen containing gas mixture which can be effectively combusted in a single ATO. The catalyst preburner will convert raw fuels into a gas mixture including hydrogen. This hydrogen containing gas mixture then mixes with the required air flow and anode tailgas and off-gas from a pressure swing adsorption unit before being introduced into the catalyst burner. The methods address the start-ups needs of an ATO as well as the requirement that an ATO be able to burn both liquid and gas fuels in a single unit.

Abstract: The present invention discloses a heat transfer unit which integrates a boiler and a gas preheater for steam generation and gas preheating. In one embodiment, the heat transfer unit of the present invention may be used in fuel processing applications. In this embodiment, the heat transfer unit may be located downstream of a combustor such as an anode tailgas oxidizer.

Abstract: The present invention discloses a hybrid combustor, such as an anode tailgas oxidizer (ATO), for fuel processing applications which combines both flame and catalytic type burners. The hybrid combustor of the present invention combines the advantages of both flame and catalytic type burners. The flame burner component of the hybrid combustor is used during start-up for the preheating of the catalytic burner component. As soon as the catalytic burner bed is preheated or lit off, the flame burner will be shut off. Optionally, the hybrid combustor may also include an integrated heat recovery unit located downstream of the catalytic burner for steam generation and for the preheating of the feed for a reformer, such as an autothermal reformer.

Abstract: The present invention discloses a fluidized bed system for the single step reforming technology for the production of hydrogen. Single step reforming combines the steam methane reforming, water gas shift, and carbon dioxide removal in a single step process of hydrogen generation. In the present invention, to address the heat transfer and the replenishment issues associated with single step reforming, the sorbent particles are fluidized. This fluidization allows the sorbent particles to be regenerated and consequently allows the optimal operating conditions for single step reforming to be maintained.

Abstract: The present invention comprises an improved antifreeze coolant composition with certain additives that serve to increase the thermal stability of the glycol component of a glycol/water coolant composition and to reduce the tendency of the glycol component to degrade under elevated thermal conditions. These additives comprise organic compounds with a carboxylic acid moiety and a hydroxyl moiety, and also tricarballylic acid. Another aspect of this invention concerns a method for improving the stability of the glycol component of a glycol/water coolant composition in engine cooling/heating systems by formulating a glycol/water coolant composition with the thermal stability additive to form an improved coolant composition, and contacting the engine cooling/heating system with the improved coolant composition.

Abstract: Methods for converting hydrocarbon fuels to hydrogen-rich reformate that incorporate a carbon dioxide fixing mechanism into the initial hydrocarbon conversion process. The mechanism utilizes a carbon dioxide fixing material to remove carbon dioxide from the reformate product stream. The removal of carbon dioxide from the product stream shifts the reforming reaction equilibrium toward higher hydrocarbon conversion with only small amounts of carbon oxides produced. Repeated absorption/desorption of carbon dioxide by the fixing materials tends to decrease the fixing capacity of the materials. Hydration of the carbon dioxide fixing materials between one or more cycles serves to sustain their fixing capacity and to enhance the efficiencies of the reforming and shift reactions occurring in the catalyst bed. Hydration can occur during reactor start-up or shut down, periodically over a number of cycles, and/or upon a monitored change in the reformate composition.

Abstract: An apparatus and method for producing a hydrogen-enriched reformate. The apparatus includes a fuel processor for converting a fuel to a reformate having fluctuations in pressure and or flow rate, means for reducing the fluctuations, a compression unit for compressing the reformate and one or more of a purification unit and a storage unit downstream of a compression unit. Means for reducing the fluctuations in the reformate can include one or more of a buffer and a conduit for providing a controlled flow of a supplemental fluid to an inlet of the compression unit. The supplemental fluid can include the compressed reformate, a hydrogen-enriched reformate, and mixtures thereof. The apparatus can include means for regulating power to the compression unit that can incrementally increase power to the compression unit particularly during start up. The purification unit can include one or more of a hydrogen selective membrane and a pressure swing adsorption unit. Methods for producing hydrogen are also disclosed.

Abstract: An apparatus and method for producing a hydrogen-enriched reformate. The apparatus includes a fuel processor for producing a reformate having fluctuations in a pressure and/or flow rate and means for reducing the fluctuations. The reformate comprises impurities that are removed by a purification unit having a plurality of adsorbent beds. A valve assembly controls the flow of reformate to the adsorbent beds based upon sensed product data generated by a product sensor. A compression unit optionally compresses the reformate prior to entering the purification unit. Means for reducing fluctuations in the pressure and/or flow rate include a buffer and/or a conduit for providing a controlled flow of a supplemental fluid to an inlet of the compression unit. A product valve can control the flow of hydrogen-enriched reformate out of the purification unit.

Abstract: An apparatus and method for producing a hydrogen-enriched reformate. The apparatus includes a fuel processor for converting a fuel to a reformate having fluctuations in pressure and or flow rate, means for reducing the fluctuations, a compression unit for compressing the reformate and one or more of a purification unit and a storage unit downstream of a compression unit. Means for reducing the fluctuations in the reformate can include one or more of a buffer and a conduit for providing a controlled flow of a supplemental fluid to an inlet of the compression unit. The supplemental fluid can include the compressed reformate, a hydrogen-enriched reformate, and mixtures thereof. The apparatus can include means for regulating power to the compression unit that can incrementally increase power to the compression unit particularly during start up. The purification unit can include one or more of a hydrogen selective membrane and a pressure swing adsorption unit. Methods for producing hydrogen are also disclosed.

Abstract: A control technique for use in a fuel processor is disclosed. In one aspect, a control system includes a subsystem manager controller the operation of a respective physical subsystem for each of a plurality of physical subsystems in the fuel processor. The subsystem managers take their direction from a master control manager. In a second aspect, the subsystem managers collectively form a layer operating in conjunction with a second layer capable of interfacing the subsystem managers to their respective physical subsystems, a third layer capable of interfacing the subsystem managers with the second layer. In a third aspect, master control manager manages the operation of each physical subsystem through a respective subsystem manager, directs state transitions of the subsystem managers, and routs interaction between the subsystem managers from the master control manager.

Abstract: An apparatus for separating liquid from a gas stream. The apparatus includes an elongated housing having a cylindrical inner surface and a gas stream inlet that is tangential to the side wall of the housing so as to cause the entering gas stream to swirl within the housing. A gas stream outlet is located at the top of the housing and a liquid outlet at the bottom. The gas stream outlet can include an elongated tubular member that extends into the housing and has an opening that is located below the housing gas stream inlet. Liquid components of the gas stream separate from the stream under the influence of centrifugal forces that are created by the swirling flow path of the stream within the housing. A liquid outlet and liquid outlet valve are provided for maintaining a minimum level of liquid within the housing so as to maintain a liquid seal within the housing. A level indicator may optionally be provided to monitor the liquid level within the housing.

Abstract: A control technique for use in a fuel processor is disclosed. In one aspect, a control system includes a subsystem manager controller the operation of a respective physical subsystem for each of a plurality of physical subsystems in the fuel processor. The subsystem managers take their direction from a master control manager. In a second aspect, the subsystem managers collectively form a layer operating in conjunction with a second layer capable of interfacing the subsystem managers to their respective physical subsystems, a third layer capable of interfacing the subsystem managers with the second layer. In a third aspect, master control manager manages the operation of each physical subsystem through a respective subsystem manager, directs state transitions of the subsystem managers, and routs interaction between the subsystem managers from the master control manager.

Abstract: An apparatus for producing hydrogen having compressor motor speed control. The apparatus includes a hydrogen generator for producing a product comprising hydrogen and a compression unit for compressing the product. The hydrogen generator can include a fuel processor having an oxidizer and a reformer. The compression unit has an induction motor and means for regulating the speed of the motor. The means for regulating the speed of the motor can include a variable frequency drive or soft start device having a plurality of switches and an adjustable ramp timer. A downstream unit including one or more of a purification unit, a second compression unit, and a storage unit is disposed downstream of the compression unit. A method for producing hydrogen is provided that includes generating a product comprising hydrogen in a hydrogen generator, compressing the product in a compression unit having an induction motor and regulating the speed of the motor in response to transient operations of the hydrogen generator.

Abstract: An apparatus and method for producing hydrogen. The apparatus includes a fuel processor, a purification unit and a system controller. The controller determines a calculated flow of reformate from the fuel processor and operates the purification unit based on the calculated flow. The calculated flow is derived from a process model of the fuel processor and known feed(s) to the fuel processor. The calculated flow of reformate is used to control the flow of reformate to adsorbent beds within the purification unit and can be used to control other materials flows within the apparatus. Means for reducing fluctuations in the pressure and/or flow rate of reformate flowing from the fuel processor to the purification unit are also disclosed. The purity of the hydrogen produced can be maintained by adjusting the operation of the purification unit in response to changes in reformate composition, pressure and/or flow rate.

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: The application of carboxylate salts for storing thermal energy is disclosed. The invention is directed to methods for the storage and use of thermal energy comprising contacting mixtures of alkali metal salts or alkali earth metal salts of carboxylic acids, storing the thermal energy in the mixture, containing the mixture in a suitable heat exchange system and using the stored thermal energy in the heat exchange system.

Abstract: A coolant subsystem for use in a fuel processor and a method for its operation are disclosed. In accordance with a first aspect, the coolant subsystem is separate from the feed to the processor reactor and is capable of circulating a coolant through the processor reactor. In accordance with a second aspect, the constituent elements of the fuel processor are housed in a cabinet, and the coolant subsystem is capable of cooling both the processor reactor and the interior of the cabinet. In various alternatives, the fuel processor can be employed to reform a fuel for a fuel cell power plant and/or may be used to provide thermal control for unrelated mechanical systems.

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 modules stacked end-to-end along a common axis. Each module includes a shell having an interior space defining a passageway for the flow of gas from a first end of the shell to a second end of the shell opposite the first end, and a processing core being contained within the interior space for effecting a chemical, thermal, or physical change to a gas stream passing axially through the module. The multi-step process includes: providing a fuel processor having a plurality of modules stacked end-to-end along a common axis; and feeding the hydrocarbon fuel successively through each of the modules in an axial direction through the tubular reactor to produce the hydrogen rich gas.

Abstract: A method and apparatus are disclosed. The apparatus includes a store of at least one historical sensor measurement, a store of potential cut-off frequencies, and a filter. Each potential cut-off frequency is associated with a respective potential difference between a sensor measurement and the stored historical sensor measurement. The filter has a cut-off frequency dynamically selected from the stored potential cut-off frequencies on the basis of a difference between the stored historical sensor measurement and a current sensor measurement. The method includes determining a difference between a current sensor measurement and a historical sensor measurement; and dynamically selecting a cut-off frequency for a filter for the current sensor measurement from the difference.

Abstract: An apparatus for converting hydrocarbon fuel to a hydrogen rich gas including a first heat exchanger for heating the hydrocarbon fuel, a first desulfurization reactor for reacting a heated hydrocarbon fuel to produce a substantially desulfurized hydrocarbon fuel, a manifold for mixing the substantially desulfurized hydrocarbon fuel with an oxygen containing gas to produce a fuel mixture, a second heat exchanger for heating the fuel mixture, an autothermal reactor including a catalyst for reacting the heated fuel mixture to produce a first hydrogen containing gaseous mixture, a second desulfurization reactor for producing a second hydrogen containing gaseous mixture that is substantially desulfurized, a water gas shift reactor for reacting the second hydrogen containing gaseous mixture to produce a third hydrogen containing gaseous mixture with a substantially decreased carbon monoxide content, and a selective oxidation reactor for reacting the third hydrogen containing gaseous mixture to produce the hydrogen