Abstract: The invention is a fuel cell (20) having a corrosion resistant and protected cathode catalyst layer (24). The cathode catalyst layer (24) includes a platinum oxygen reduction catalyst and an oxygen evolution catalyst selected from the group consisting of catalysts that are more active than platinum for oxygen evolution. The oxygen evolution catalyst may be uniformly applied within the cathode catalyst layer, or non-uniformly applied to identified high corrosion areas (82) (84) of the cathode catalyst layer (24). The cathode catalyst layer (24) may include heat-treated carbon support material, and/or a heat-treated carbon black within a diffusion layer (40) supporting the cathode catalyst layer (24). The fuel cell (20) may also include an anode catalyst layer (22) having a poor oxygen reduction catalyst having a greater oxygen reduction over potential than platinum.

Abstract: A fuel cell power plant includes a fuel cell having a membrane electrode assembly (MEA), disposed between an anode support plate and a cathode support plate, the anode and/or cathode support plates include a hydrophilic substrate layer having a predetermined pore size. The pressure of the reactant gas streams is greater than the pressure of the coolant stream, such that a greater percentage of the pores within the hydrophilic substrate layer contain reactant gas rather than water. Any water that forms on the cathode side of the MEA will migrate through the cathode support plate and away from the MEA. Controlling the pressure also ensures that the coolant water will continually migrate from the coolant stream toward the anode side of the MEA, thereby preventing the membrane from becoming dry. Proper pore size and a pressure differential between coolant and reactants improves the electrical efficiency of the fuel cell.

Abstract: In a near ambient pressure operated auto-thermal reformer fuel gas system, a precooler between the auto-thermal reformer and shift converter. The precooler includes a spraying water inlet, an inlet for the reformed gas and a packing of high surface area material which increases the available surface area for water evaporation in the precooler so as to effectively cool the hot reformed gas.

Abstract: A membrane electrode assembly includes an anode including a hydrogen oxidation catalyst; a cathode; a membrane disposed between the anode and the cathode; and a peroxide decomposition catalyst positioned in at least one position selected from the group consisting of the anode, the cathode, a layer between the anode and the membrane and a layer between the cathode and the membrane wherein the peroxide decomposition catalyst has selectivity when exposed to hydrogen peroxide toward reactions which form benign products from the hydrogen peroxide. The peroxide decomposition catalyst can also be positioned within the membrane. Also disclosed is a power-generating fuel cell system including such a membrane electrode assembly, and a process for operating such a fuel cell system.

Abstract: In a near ambient pressure operated auto-thermal reformer fuel gas system, a precooler between the auto-thermal reformer and shift converter. The precooler includes a spraying water inlet, an inlet for the reformed gas and a packing of high surface area material which increases the available surface area for water evaporation in the precooler so as to effectively cool the hot reformed gas.

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 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 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 reversing manifolds which form a part of each sub-assembly.

Abstract: Fuel Cell Having a Hydrophilic Substrate Layer A fuel cell power plant includes a fuel cell having a membrane electrode assembly (MEA), disposed between an anode support plate and a cathode support plate, the anode and/or cathode support plates include a hydrophilic substrate layer having a predetermined pore size. The pressure of the reactant gas streams is greater than the pressure of the coolant stream, such that a greater percentage of the pores within the hydrophilic substrate layer contain reactant gas rather than water. Any water that forms on the cathode side of the MEA will migrate through the cathode support plate and away from the MEA. Controlling the pressure also ensures that the coolant water will continually migrate from the coolant stream toward the anode side of the MEA, thereby preventing the membrane from becoming dry. Proper pore size and a pressure differential between coolant and reactants improves the electrical efficiency of the fuel cell.

Abstract: A fuel cell system (10) having a membrane/electrode assembly (MEA) (16) is provided with the means and technique for quickly inerting the MEA without requiring a nitrogen purge. A first fine pore plate (14) is positioned at an anode side of the MEA and defines a coolant flow field (36) and typically also, a fuel reactant flow field (48). A second fine pore plate (12) is positioned at a cathode side of the MEA and defines a lo coolant flow field (36) and typically also, an oxidant reactant flow field (38). A respective wettable substrate (22,26) is positioned between the MEA and each of the first and second fine pore plates, and is adjacent to the fine pore plates.

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: A fine pore enthalpy exchange barrier is disclosed for use with a fuel cell power plant. The barrier includes a support matrix that defines pores and a liquid transfer medium that fills the pores creating a gas barrier. An inlet surface of the fine pore enthalpy exchange barrier is positioned in contact with a process oxidant inlet stream entering a fuel cell power plant, and an opposed exhaust surface of the barrier is positioned in contact with an exhaust stream exiting the plant so that water and heat exchange from the exhaust stream directly into the process oxidant inlet stream to heat and humidify the stream as it enters the plant. The liquid transfer medium may include water, aqueous salt solutions, aqueous acid solutions, or organic antifreeze water solutions.

Abstract: Solid polymer membrane fuel cell water which collects on the oxidant side of the membrane is removed from the active area of the cells in a fuel cell power plant by being absorbed into porous carbon bodies, one of which contacts the membrane. Some of the treated carbon bodies can also be used to supply water to the anode side of the membrane in order to minimize anode side membrane drying. The pores in the carbon body are partially filled, or coated, with precursors of metal oxyhydroxide compounds, which, when converted, will impart increased wettability and water absorption capacity to the carbon body. Hydroxides of the filler compounds are applied to the carbon body and are heated to convert them into oxyhydroxides. As used in this document, the term “oxyhydroxide” includes oxyhydroxides, oxyhydroxide hydrates, and oxide hydrates. Processing temperatures are low enough so as to not subject the bodies being impregnated to destabilization.

Abstract: A fuel gas reformer assembly for use in a fuel cell power plant includes fuel gas passages, some of which contain a particulate alumina packing in which a vaporized steam-hydrocarbon fuel stream mixture is heated. The walls of the fuel gas passages are provided with an alumina coating which protects the walls of the passages from corrosion. The alumina coating of the walls, and alumina packing are both overlain by an alkaline earth metal oxide layer, such as a calcium oxide layer, that acts to limit carbon build-up on the surfaces of the coated passage walls. Limiting of carbon build-up in the reformer passages prevents premature clogging of the passages. The carbon build-up-limiting layer is formed on components of the reformer passages by applying a water-based slurry of alkaline earth metal compounds to the reformer passage surfaces, and then drying the slurry so as to solidify it.

Abstract: The reactant manifolds and corners of a molten carbonate fuel cell stack are sealed with particulate lithium aluminate members which are sufficiently porous so as to resist significant electrolyte migration therethrough. The seal members which are disposed in vertical planes of the stack are preferentially formed from lithium aluminate grains which are bonded together by a silica-free glass binder. The seal members which are disposed in horizontal planes in the stack are preferably formed from lithium aluminate grains which are bonded together by surface hydrolysis. Alumina-clad stainless steel labyrinth seal members are associated with each of the horizontal seal members to inhibit electrolyte migration from the cell electrolyte matrices to the vertical seal members.

Abstract: A lanthanum chromite ceramic powder mixture that consists essentially of 1 mol of LaCr.sub.1-x M.sub.x O.sub.3, where M is a divalent metal selected from the group consisting of magnesium, calcium and mixtures thereof and x ranges from 0.03 to 0.3; y mols of B.sub.2 O.sub.3, where y ranges from 0.005 to 0.04; and z mols of La.sub.2 O.sub.3, where the ratio z/y ranges from 1.1 to 3. The mixture is formed into powder compacts and sintered to near full density at temperatures as low as 1400.degree. C.

Abstract: Water soluble precursors of ceramic compounds are emulsified in an organic fluid that is subsequently heated to remove the free water from the emulsion droplets and further heated in a partial oxygen atmosphere to form a char. The carbon in the char maintains the separation between the dried droplet-derived particles. This char may then be heated in air to oxidize and remove the carbon, to calcine the ceramic, and to controllably produce a fine powder of spherical particles having a narrow size distribution.