Abstract: In an embodiment, a hydrogen monitoring system comprises a plurality of sensing elements that individually comprise a working electrode, a counter electrode, an insulating layer located in between the working electrode and the counter electrode, a catalyst located on an end of both the working electrode and the counter electrode, an electrolyte located on the end of the sensing elements on both the working electrode and the counter electrode, between the working electrode and the counter electrode, and in contact with the catalyst, and an electrical circuit located on an opposite end of the sensing element that connects the working electrode and the counter electrode.

Abstract: In an embodiment, a hydrogen monitoring system comprises a plurality of sensing elements that individually comprise a working electrode, a counter electrode, an insulating layer located in between the working electrode and the counter electrode, a catalyst located on an end of both the working electrode and the counter electrode, an electrolyte located on the end of the sensing elements on both the working electrode and the counter electrode, between the working electrode and the counter electrode, and in contact with the catalyst, and an electrical circuit located on an opposite end of the sensing element that connects the working electrode and the counter electrode.

Abstract: In an embodiment, a hydrogen monitoring system comprises a plurality of sensing elements that individually comprise a working electrode, a counter electrode, an insulating layer located in between the working electrode and the counter electrode, a catalyst located on an end of both the working electrode and the counter electrode, an electrolyte located on the end of the sensing elements on both the working electrode and the counter electrode, between the working electrode and the counter electrode, and in contact with the catalyst, and an electrical circuit located on an opposite end of the sensing element that connects the working electrode and the counter electrode.

Abstract: In an embodiment, a hydrogen monitoring system comprises a plurality of sensing elements that individually comprise a working electrode, a counter electrode, an insulating layer located in between the working electrode and the counter electrode, a catalyst located on an end of both the working electrode and the counter electrode, an electrolyte located on the end of the sensing elements on both the working electrode and the counter electrode, between the working electrode and the counter electrode, and in contact with the catalyst, and an electrical circuit located on an opposite end of the sensing element that connects the working electrode and the counter electrode.

Abstract: The present disclosure provides for improved electrochemical devices (e.g., fuel cells, metal air batteries, ultra capacitors, etc.) and components therefore. More particularly, the present disclosure provides for improved systems and methods for producing materials, membranes, electrode assemblies (e.g., membrane electrode assemblies) and electrochemical devices employing the membranes and/or electrode assemblies. The present disclosure provides for improved systems and methods for producing high activity materials, membranes and/or electrode assemblies (e.g., MEAs) for use in electrochemical devices, wherein the high activity membranes and/or electrode assemblies include at least one inorganic acid. In exemplary embodiments, the present disclosure provides for improved systems and methods for producing high activity membranes and/or electrode assemblies (e.g.

Abstract: An integrated fuel cell stack assembly (26) and selective oxidizer bed assembly (200) is provided. The fuel cell stack assembly (26) also includes a number of fuel cells. A fuel inlet manifold (22) and fuel inlet plenum to cell stack (38) manifold are arranged in fluid communication with the fuel stack assembly (26) for supplying to and exhausting from, respectively, the fuel supply in the fuel cells in the fuel stack assembly (26). The bed resides in said fuel inlet manifold. The bed includes a selective oxidation catalyst with a heat exchange fluid conduit routed therethrough. Oxygen-containing gas is supplied into the bed via the input plenum. The temperature of the internal selective oxidizer bed is controlled by the fluid conduit in the bed to reduce carbon monoxide in the fuel.

Abstract: The invention is a reformate fuel treatment system for a fuel cell power plant that includes at least one fuel cell for generating electricity from process oxidant and reducing fluid reactant streams; fuel processing components including a steam supply and a reformer for producing a hydrogen enriched reformate fuel for the fuel cell from a hydrocarbon fuel; and, an ammonia removal apparatus that treats the reformate fuel to make it appropriate for supplying hydrogen to an anode electrode of the fuel cell. The ammonia removal apparatus may be a disposable ammonia scrubber, an ammonia scrubbing cool water bed and an ammonia stripping warm water bed, a pair of first and second regenerable scrubbers, or a single regenerable ammonia scrubber.

Abstract: An apparatus for the thermal management of an electrochemical fuel cell assembly, wherein a plurality of thermal management loops in contact with the fuel cell assembly are utilized to maintain the fuel cell assembly above freezing or, alternatively, raise the fuel cell assembly above freezing. The thermal management loops are in thermal communication with the fuel cell assembly as well as each other, but are diffusably isolated from one another.

Abstract: A fuel gas processing system is operable to remove substantially all of the sulfur present in a hydrocarbon fuel supply used to power a fuel cell power plant in a mobile vehicular environment. The power plant fuel can be gasoline, diesel fuel, kerosene, fuel oil, natural gas, or another fuel which contains relatively high levels of organic sulfur compounds such as mercaptans, sulfides, disulfides, and the like. The hydrocarbon fuel supply is passed through a nickel reactant desulfurizer bed wherein essentially all of the sulfur in the organic sulfur compounds react with the nickel reactant, and are converted to nickel sulfide while the desulfurized fuel continues through the remainder of the fuel processing system. The fuel cell power plant and the processing system can be used to power a mobile vehicle, such an automobile, truck, bus, or the like. An auxiliary supply of hydrogen is provided in order to power the fuel cell power plant during start up of the fuel processing system.

Abstract: An environmental compensation apparatus for an electrochemical fuel cell assembly, wherein a compressible material is dispersed within a coolant flow of the fuel cell assembly and is utilized to compensate for the expansion of the coolant when said fuel cell assembly is subjected to harsh environmental conditions. The compressible material is formed as a plurality of either polymeric or elastomer microspheres, each microsphere having a diameter larger than the pores of an anode or cathode flow field plate, yet smaller than the diameter of a coolant channel.

Abstract: A fuel processing system is operable to remove substantially all of the sulfur present in an undiluted hydrocarbon fuel stock supply used to power a fuel cell power plant in a mobile environment, such as an automobile, bus, truck, boat, or the like, or in a stationary environment. The power plant hydrogen fuel source can be gasoline, diesel fuel, naphtha, light hydrocarbon fuels such as butane, propane, natural gas, or other like fuels which contain relatively high levels of organic sulfur compounds such as mercaptans, sulfides, disulfides, and the like. The undiluted hydrocarbon fuel supply is passed through a nickel desulfurizer bed wherein essentially all of the sulfur in the organic sulfur compounds react with the nickel reactant, and are converted to nickel sulfide while the desulfurized organic remnants continue through the remainder of the fuel processing system. The system does not require the addition of steam or a hydrogen source to the fuel stream prior to the desulfurizing step.

Abstract: A fuel processing system is operable to remove substantially all of the sulfur present in an undiluted hydrocarbon fuel stock supply used to power a fuel cell power plant in a mobile environment, such as an automobile, bus, truck, boat, or the like, or in a stationary environment. The power plant hydrogen fuel source can be gasoline, diesel fuel, naphtha, light hydrocarbon fuels such as butane, propane, natural gas, or other like fuels which contain relatively high levels of organic sulfur compounds such as mercaptans, sulfides, disulfides, and the like. The undiluted hydrocarbon fuel supply is passed through a nickel desulfurizer bed wherein essentially all of the sulfur in the organic sulfur compounds react with the nickel reactant, and are converted to nickel sulfide while the desulfurized organic remnants continue through the remainder of the fuel processing system. The system does not require the addition of steam or a hydrogen source to the fuel stream prior to the desulfurizing step.

Abstract: A fuel gas catalyst bed for use in a fuel cell power plant is formed from a monolithic open cell foam component, the open cell lattice of which forms gas passages through the catalyst bed. The monolithic component has a lattice of internal open cells which are both laterally and longitudinally interconnected so as to produce a diffuse gas flow pattern through the catalyst bed. All areas of the monolithic component which form the gas flow pattern are provided with an underlying high porosity wash coat layer. The porous surface of the wash coat layer is provided with a nickel catalyst layer, or a noble metal catalyst layer, such as platinum, rhodium, palladium, or the like, over which the gas stream being treated flows. The base foam lattice can be a metal such as aluminum, stainless steel, a steel-aluminum alloy, a nickel alloy, a ceramic, or the like material which can be wash coated.

Abstract: A fuel processing system is operable to remove substantially all of the sulfur present in gasoline or diesel fuel used for operating an internal combustion engine. The fuel supply is passed through a nickel reactant desulfurizer bed wherein essentially all of the sulfur in organic sulfur compounds in the fuel combine with the nickel reactant in the desulfurizer bed, and are converted to nickel sulfide. The desulfurizing system can operate at ambient or elevated pressures. The fuel can be treated either in a liquid phase or in a vapor phase. The sulfur scrubbing operation can be performed either in a vehicle while the latter is being operated, or at the fueling station (gas station) prior to sale to the end user. The amount of sulfur in the fuel can be lowered to less than about 0.05 ppm. This extends the life of the catalytic converters in vehicles, reduces corrosion of parts of the internal combustion engine, and provides an environmentally compatible system.

Abstract: A proton exchange membrane fuel cell has a noble metal or noble metal alloy catalyst 15 disposed in its air inlet manifold 13. During start up, a fuel cell is warmed to operating temperature by introducing a small amount of hydrogen into a flow of air to the air inlet 12 of the fuel cell where they react with the catalyst to produce heat at subflame temperatures. The adiabatic temperature rise of the gas stream is limited to about 150.degree. F. by limiting the hydrogen to about one volume percent of the fuel/oxidant mixture, thereby to be capable of raising the fuel cell temperature, for instance, from -40.degree. C. (-40.degree. F.) to about +45.degree. C. (+113.degree. F.), without flame, explosion or drying out of the membrane.

Abstract: The present invention relates to a method and apparatus for creating steam from the cooling stream of a proton exchange membrane (PEM) fuel cell. As the cooling stream exits the PEM fuel cell, a portion of the cooling fluid is extracted from the circulating cooling stream, thereby creating a secondary stream of cooling fluid. This secondary stream passes through a restriction, which decreases the pressure of the secondary stream to its saturation pressure, such that when the secondary stream enters a flash evaporator it transforms into steam. Creating steam from the cooling stream of a PEM fuel cell power plant provides the fuel processor with a co-generated source of steam without adding a significant amount of auxiliary equipment to the power plant.

Abstract: A PEM fuel cell system includes a PEM fuel cell that has an input and output port each for fuel or reformate, process air and coolant. A predetermined fraction of volume of moistened exhaust air leaving the air output port of the fuel cell is diverted back and combined with fresh, air at ambient temperature entering the air input port of the PEM fuel cell to maintain water balance in the fuel cell at high ambient operating temperatures. The recycle-to-air vent ratio is controlled by a processor which adjusts the recycle flow based on the ambient temperature and the power level of the fuel cell.

Abstract: The fuel cell power plant has a closed water circulation system whose only source of fresh water is the electrochemical reaction in the power section. The water becomes contaminated with ammonia and carbon dioxide in the fuel contact cooler and the ammonia and carbon dioxide are stripped out of the water by steam produced by operating the plant. The ammonia and carbon dioxide-laden steam is vented from the plant. The amount of water lost from the plant as steam is less than the amount of available water produced in the electrochemical reaction.

Abstract: A method of forming thin, uniform braze joints is effected through the use of curtain coating. Braze powder is admixed with a liquid polymeric binder to form a slurry. The slurry is forced through the slots in a curtain coating head and deposited on at least one of the metal surfaces to be bonded together. The method has particular utility for bonding fin/plate sections of a heat exchanger where the fins have a U-shaped cross section. The slurry is deposited on the top portion of the fin and the side portion of the fin and wiped from the top portion leaving braze material primarily on the side wall portion. When the plates are contacted to the fins and heating performed, a bond is effected with maximum plate-to-fin contact for high heat transfer and a strong braze joint.