Abstract: One embodiment of a method of operating a NOx abatement system comprises: introducing an exhaust stream to an ammonia generator in a normal flow direction, adsorbing NOx from the exhaust stream in the ammonia generator, diverting the exhaust stream around the ammonia generator, introducing hydrogen to the ammonia generator in a direction opposite the normal flow direction, and generating ammonia within the ammonia generator.

Abstract: A fuel cell module having four sheet metal parts stamped from flat stock. The parts do not require any forming operations such as folding or dishing. Each part may have a different thickness to suit its function. The first part is a cell mounting frame for receiving and supporting a PEN fuel cell element. The second part is a cathode spacer, the thickness of the spacer determining the height of the cathode air flow field. The third part is an anode spacer, the thickness of spacer determining the height of the anode fuel flow field. The fourth part is a separator plate for separating the anode gas flow in one cell from the cathode air flow in an adjacent cell in a fuel cell stack. The four plates are joined by welding or brazing and may be assembled in any order or combination which suits the assembly process. Any desired number of modules may be stacked together to form a fuel cell stack.

Abstract: One embodiment of a method of operating a NOx abatement system comprises: introducing an exhaust stream to an ammonia generator in a normal flow direction, adsorbing NOx from the exhaust stream in the ammonia generator, diverting the exhaust stream around the ammonia generator, introducing hydrogen to the ammonia generator in a direction opposite the normal flow direction, and generating ammonia within the ammonia generator.

Abstract: In one embodiment, a method of heating an exhaust treatment device can comprise: generating reformate in a reformer, wherein the reformate comprises hydrogen; introducing oxygen to the reformate prior to combining the reformate with another stream; combusting a portion of the reformate and generating an exotherm to form heated reformate; and introducing the heated reformate to the exhaust treatment device. In one embodiment the exhaust system can comprise: a reformer; a reformate conduit disposed in physical communication with a reformate outlet of the reformer; an exhaust treatment device disposed in fluid communication with the reformer; and an oxygen supply disposed in fluid communication with the reformate conduit such that oxygen can be introduced into the reformate conduit upstream of a reformate conduit outlet, wherein the reformate conduit outlet is disposed in physical communication with an exhaust conduit and/or the exhaust treatment device.

Abstract: A method for severing a solid-oxide fuel cell bi-layer element including a structural anode and an electrolyte layer, comprising the steps of orienting the bi-layer element such that the surface thereof is accessible to laser treatment; impinging a laser beam on the electrolyte surface; moving the impinged laser beam past the surface along a path in a plane corresponding to the desired severed edge to form a groove in the element extending partially through the element to a predetermined depth; and applying a bending moment across the groove to cause the element to break into first and second portions. The groove depth is preferably about 15% of the total thickness of the element.

Abstract: In one embodiment, a flow switch can comprise: a deflector having a diverging upstream portion; an aperture located in a downstream portion of the deflector; and a divider disposed downstream of the deflector. The deflector can be capable of diverting a fluid stream that contacts the upstream portion, around the deflector. The aperture can be capable of allowing a flow of a displacing fluid such that the displacing fluid can inhibit the diverted fluid stream from converging to pass through the divider. The divider can be capable of allowing a flow of the displacing fluid therethrough.

Abstract: A fuel cell stack having perforated baffles disposed within the cathode air flow spaces of the stack for distributing air across the cathode and interconnect surfaces in a predetermined pattern to minimize temperature variations on the cathode surface. A baffle comprises at least one element inclined to the air flow direction and having a pattern of perforations for the passage of air therethrough. A baffle may include one or more additional elements to form, for example, a V shape within the cathode air flow space. The perforations may be in the form of slots, holes, or any other shape as desired. The pattern of perforations may be varied both longitudinally and transversely of the baffle element to modulate air flow both longitudinally and transversely as may be required.

Abstract: A NOx abatement system comprising: a first NOx adsorber (18) capable of being disposed in-line and downstream of and in fluid communication with an engine (12); a selective catalytic reduction catalyst (20) disposed in-line and downstream of and in direct fluid communication with the first NOx adsorber (18), wherein the selective catalytic reduction catalyst (20) is capable of storing ammonia; and an off-line reformer (24) disposed in selective communication with and upstream of the first NOx adsorber (18) and the selective catalytic reduction catalyst (20), wherein the reformer (24) is capable of producing a reformate comprising primarily hydrogen and carbon monoxide.

Abstract: A load frame with mechanical springs for providing compression to a fuel cell stack during assembly and operation of a fuel cell assembly. The stack assembly load frame includes a base plate for supporting the stack, a moveable spring holder above the stack, a retaining plate above the spring holder, and tubular supports or rods retaining the post-sintered spacing established by the applied load defining the spacing of the base plate from the retaining plate. A spring for maintaining compression in each stack is positioned between the spring holder and the retaining plate. The invention further comprises a method for assembling a fuel cell assembly to provide an adequate compressive load to the stack during assembly and operation.

Abstract: A reformer comprises a housing comprising a housing inner surface, a housing outer surface, and an inlet; an ignition housing comprising an ignition housing inner surface, an ignition housing outer surface, an opening, and a turbulent flow generator bordering a portion of the opening, wherein the ignition housing is disposed within the housing; a chamber defined by the housing inner surface and the ignition housing outer surface in fluid communication with the inlet and the opening; and a catalytic substrate disposed within the ignition housing in fluid communication with the opening.

Abstract: A fuel cell assembly having manifold means for providing fuel and air to, and removing spent fuel and air from, flow passageways across the anodes and cathodes in a fuel cell stack. The sizes and proportions of the supply and return manifolds are optimized, and the total cross-sectional area of the return manifold is about twice the cross-sectional area of the supply manifold. The pressure drop in the manifolds is less than about one-quarter of the total pressure drop across the anode and cathode passageways in the stack, which ratio may be attained by adjusting the thickness of the anode and cathode spacers and/or the size of the chimneys. Widthwise uniformity of flow across the anodes and cathodes is improved by forming each of the manifolds as a plurality of smaller, parallel flow conduits.

Abstract: In one embodiment, the method of producing a ceramic assembly includes: disposing an electrode precursor on an electrolyte precursor having an electrolyte sintering shrinkage, disposing a stabilizer precursor having a stabilizer sintering shrinkage on the electrode precursor on a side opposite the electrolyte precursor to form a precursor assembly, and sintering the precursor assembly to form the ceramic assembly comprising a stabilizer layer, electrode, and electrolyte. The difference between the electrolyte sintering shrinkage and the stabilizer sintering shrinkage is less than or equal to ±1% and a surface of the ceramic assembly has less than or equal to about 5.0 degrees camber, as measured from the horizontal plane.

Abstract: A gas treatment system and method for using the same is disclosed. The gas treatment system, comprises: a non-thermal plasma reactor; and a catalyst composition disposed within said non-thermal plasma reactor, said catalyst composition comprising a MZr4(PO4)6, wherein M is a metal selected from the group consisting of platinum, palladium, ruthenium, silver, rhodium, osmium, iridium, and combinations comprising at least one of said foregoing metals. The process comprises exposing said gas to a plasma field and to the catalyst composition.

Abstract: An electrically-conductive mesh spacer incorporated into the hydrogen and air gas flow spaces between each anode and cathode and its adjacent interconnect in a fuel cell stack. The mesh is formed of metal strands and is formed into a predetermined three-dimensional pattern to make contact at a plurality of points on the surfaces of the electrode and the interconnect element. The formed mesh spacer is secured as by brazing to the interconnect element at a plurality of locations to form an interconnect, which preserves the pattern during assembly of a fuel cell stack. The height of the formed pattern is greater than the height of a gas flow space after fuel cell assembly, such that the mesh spacer is slightly compressed during assembly of a fuel cell stack. Because the metal mesh is both compliant and resilient, the compressed spacer is continuously urged into mechanical and electrical contact with its electrode over all temperatures and pressures to which the fuel cell assembly may be subjected during use.

Abstract: A base manifold for a modular solid oxide fuel cell assembly comprises a plurality of receiving areas for receiving a plurality of solid oxide fuel cell stacks; a fuel inlet passageway disposed between a manifold fuel inlet port and a plurality of stack fuel inlet ports; an oxidant inlet passageway disposed between a manifold oxidant inlet port and a plurality of stack oxidant inlet ports; a fuel outlet passageway disposed between a plurality of stack fuel outlet ports and a manifold fuel outlet port; and an oxidant outlet passageway disposed between a plurality of stack oxidant outlet ports and a manifold oxidant outlet port.

Abstract: A load frame with mechanical springs for providing compression to a fuel cell stack during assembly and operation of a fuel cell assembly. The stack assembly load frame includes a base plate for supporting the stack, a moveable spring holder above the stack, a retaining plate above the spring holder, and tubular supports or rods retaining the post-sintered spacing established by the applied load defining the spacing of the base plate from the retaining plate. A spring for maintaining compression in each stack is positioned between the spring holder and the retaining plate. The invention further comprises a method for assembling a fuel cell assembly to provide an adequate compressive load to the stack during assembly and operation.

Abstract: A passive gas spring disposed within a fuel cell assembly adjacent a fuel cell stack for maintaining the stack under compression at elevated temperatures. The spring includes at least one membrane formed of a metal alloy stable at the operating temperatures required of the fuel cell assembly. The membrane closes a chamber for retaining an amount of gas. As temperature of the assembly changes, differential thermal expansion of fuel cell components and supporting structural elements can cause height mismatches between the stack and the supporting structure, otherwise resulting in a loss of compression in the assembly. Because the temperature of the gas also increases, however, the spring force of the gas spring increases, thereby maintaining compressive load on the various assembly seals. A mechanical spring may also be provided.

Abstract: A fuel cell assembly having manifold means for providing fuel and air to, and removing spent fuel and air from, flow passageways across the anodes and cathodes in a fuel cell stack. The sizes and proportions of the supply and return manifolds are optimized, and the total cross-sectional area of the return manifold is about twice the cross-sectional area of the supply manifold. The pressure drop in the manifolds is less than about one-quarter of the total pressure drop across the anode and cathode passageways in the stack, which ratio may be attained by adjusting the thickness of the anode and cathode spacers and/or the size of the chimneys. Widthwise uniformity of flow across the anodes and cathodes is improved by forming each of the manifolds as a plurality of smaller, parallel flow conduits.

Abstract: A fuel cell module having four sheet metal parts stamped from flat stock. The parts do not require any forming operations such as folding or dishing. Each part may have a different thickness to suit its function. The first part is a cell mounting frame for receiving and supporting a PEN fuel cell element. The second part is a cathode spacer, the thickness of the spacer determining the height of the cathode air flow field. The third part is an anode spacer, the thickness of spacer determining the height of the anode fuel flow field. The fourth part is a separator plate for separating the anode gas flow in one cell from the cathode air flow in an adjacent cell in a fuel cell stack. The four plates are joined by welding or brazing and may be assembled in any order or combination which suits the assembly process. Any desired number of modules may be stacked together to form a fuel cell stack.

Abstract: A solid oxide fuel cell is disclosed. The solid oxide fuel cell comprises an electrolyte disposed between and in ionic communication with a first electrode and a second electrode to form an electrochemical cell. At least one spacer is disposed in contact with the electrochemical cell. A mat is disposed adjacent to the spacer. A method for making a solid oxide fuel cell is also disclosed.