Abstract: An integrated autothermal reformer/recuperator unit (10) is provided for reforming a feed gas flow to produce a reformate flow. The unit (10) includes a cylindrical housing (18) having a feed gas inlet (26) and a reformate flow outlet (32) located adjacent a first end (20) of the cylindrical housing (18). An autothermal reformer catalyst structure (12) is located in the housing and spaced from the first end, and a recuperator heat exchanger (16) is located in the housing (18) between the first end (20) and the catalyst structure (12).

Abstract: A catalytic reactor/heat exchange device (10) is provided for generating a catalytic reaction in a reaction fluid flow (12) and transferring heat to a cooling fluid flow (14). The device includes reaction flow channels (20) with turbulators (30) therein. The turbulators (30) include an initial portion (40) and a selected portion (34) that includes a catalytic layer or coating (36) to initiate the desired catalytic reaction at a location (38) located downstream from the initial portion (40). In some preferred forms, each of the selected portions (34) of the turbulators (30) include at least one downstream section (103, 120) wherein the heat transfer performance has been intentionally reduced to improve performance of the device (10) during start up conditions.

Abstract: A combustor preheater (94) is provided for use in a fuel processor (20) to preheat a combustor feed (40) by transferring heat from a post water-gas shift reformate flow (32) to the combustor feed (40). The combustor preheater (94) includes a housing (92) defining first and second axially extending, concentric annular passages in heat transfer relation to each other; a first convoluted fin (96) located in the first passage to direct the post water-gas shift reformate flow (32) therethrough and a second convoluted fin (98) located in the second passage to direct the combustor feed therethrough.

Abstract: An integrated steam reformer/combustor assembly (42) is provided for use in a fuel processor (20) that supplies a steam/fuel feed mix (34) to be reformed in the assembly and a combustor feed (40) to be combusted in the assembly (42). The assembly (42) includes a housing (44,58) defining first and second axially extending, concentric annular passages in heat transfer relation to each other; a first convoluted fin (46) located in the first passage to direct the feed mix therethrough, the first convoluted fin coated with a catalyst that induces a desired reaction in the feed mix; and a second convoluted fin (50) located in the second passage to direct the combustor feed therethrough, the second convoluted fin coated with a catalyst that induces a desired reaction in the combustor feed.

Abstract: A recuperative heat exchanger (36) is provided for use in a fuel processor (20), the heat exchanger (36) transferring heat from a fluid flow (34) at one stage of a fuel processing operation to the fluid flow (32) at another stage of the fuel processing operation. The heat exchanger (36) includes a housing (56) defining first and second axially extending, concentric annular passages in heat transfer relation to each other; a first convoluted fin (70) located in the first passage to direct the fluid flow therethrough; and a second convoluted fin (72) located in the second passage to direct the fluid flow therethrough.

Abstract: A fuel processing system is provided wherein heat is transferred from a reformate flow (32) downstream from a water-gas shift (38) to both a) a combustor feed flow (40) that is supplied to a combustor (25); and b) a water flow (26) that is supplied to a reformer feed mix (34) for a steam reformer (28).

Abstract: The locating problems of endwise insertion of baffles into tubular heat exchanger headers and/or weakness problems resulting from slotting tubular heat exchanger headers for receipt of baffles are avoided in a heat exchanger including opposed headers 10, 12, at least one of which is a header tube 12 having a plurality of slots 26, 30 in a side thereof. A plurality of generally parallel tubes 14 extend between the headers 10, 12 and enter an associated one of the slots 26, 30, while a baffle is located in the header tube 12 and divides the same into two discrete sections and includes a collar 40 about an end 28 of one of the parallel tubes 14.

Abstract: A mounting bracket for a heat exchanger of the type defined by a core having tubes and fins assembled together. The mounting bracket is adapted to extend between a pair of spaced plates between which the core is disposed. A first securing mechanism is associated with a first end of the mounting bracket. It is adapted to cooperate with one of the plates for interlocked pivotal movement of the mounting bracket relative to the other of the plates. The first securing mechanism accommodates movement from a position where the second end of the mounting bracket is spaced from the other of the plates to a position where the second end of the mounting bracket is adjacent the other of the plates. A second securing mechanism is associated with a second end of the mounting bracket. It is adapted to cooperate with the other of the plates for locked engagement of the mounting bracket to the other of the plates.