Abstract: The invention provides a method for reforming fuel, the method comprising contacting the fuel to an oxidation catalyst so as to partially oxidize the fuel and generate heat; warming incoming fuel with the heat while simultaneously warming a reforming catalyst with the heat; and reacting the partially oxidized fuel with steam using the reforming catalyst.

Abstract: The invention provides a fuel processor comprising a linear flow structure having an upstream portion and a downstream portion; a first catalyst supported at the upstream portion; and a second catalyst supported at the downstream portion, wherein the first catalyst is in fluid communication with the second catalyst. Also provided is a method for reforming fuel, the method comprising contacting the fuel to an oxidation catalyst so as to partially oxidize the fuel and generate heat; warming incoming fuel with the heat while simultaneously warming a reforming catalyst with the heat; and reacting the partially oxidized fuel with steam using the reforming catalyst.

Abstract: An improved fuel processor for fuel cells is provided whereby the startup time of the processor is less than sixty seconds and can be as low as 30 seconds, if not less. A rapid startup time is achieved by either igniting or allowing a small mixture of air and fuel to react over and warm up the catalyst of an autothermal reformer (ATR). The ATR then produces combustible gases to be subsequently oxidized on and simultaneously warm up water-gas shift zone catalysts. After normal operating temperature has been achieved, the proportion of air included with the fuel is greatly diminished.

Abstract: Provided herein are methods and devices to enrich trace quantities of impurities in gaseous mixtures, such as hydrogen fuel. The methods and devices rely on concentration of impurities so as to allow the detection of the impurities using commonly-available detection methods.

Abstract: The invention provides a fuel processor comprising a linear flow structure having an upstream portion and a downstream portion; a first catalyst supported at the upstream portion; and a second catalyst supported at the downstream portion, wherein the first catalyst is in fluid communication with the second catalyst. Also provided is a method for reforming fuel, the method comprising contacting the fuel to an oxidation catalyst so as to partially oxidize the fuel and generate heat; warming incoming fuel with the heat while simultaneously warming a reforming catalyst with the heat; and reacting the partially oxidized fuel with steam using the reforming catalyst.

Abstract: A method of producing a H2 rich gas stream includes supplying an O2 rich gas, steam, and fuel to an inner reforming zone of a fuel processor that includes a partial oxidation catalyst and a steam reforming catalyst or a combined partial oxidation and stream reforming catalyst. The method also includes contacting the O2 rich gas, steam, and fuel with the partial oxidation catalyst and the steam reforming catalyst or the combined partial oxidation and stream reforming catalyst in the inner reforming zone to generate a hot reformate stream. The method still further includes cooling the hot reformate stream in a cooling zone to produce a cooled reformate stream. Additionally, the method includes removing sulfur-containing compounds from the cooled reformate stream by contacting the cooled reformate stream with a sulfur removal agent.

Abstract: An improved fuel processor for fuel cells is provided whereby the startup time of the processor is less than sixty seconds and can be as low as 30 seconds, if not less. A rapid startup time is achieved by either igniting or allowing a small mixture of air and fuel to react over and warm up the catalyst of an autothermal reformer (ATR). The ATR then produces combustible gases to be subsequently oxidized on and simultaneously warm up water-gas shift zone catalysts. After normal operating temperature has been achieved, the proportion of air included with the fuel is greatly diminished.

Abstract: An improved fuel processor for fuel cells is provided whereby the startup time of the processor is less than sixty seconds and can be as low as 30 seconds, if not less. A rapid startup time is achieved by either igniting or allowing a small mixture of air and fuel to react over and warm up the catalyst of an autothermal reformer (ATR). The ATR then produces combustible gases to be subsequently oxidized on and simultaneously warm up water-gas shift zone catalysts. After normal operating temperature has been achieved, the proportion of air included with the fuel is greatly diminished.

Abstract: A method for reforming a sulfur-containing carbonaceous fuel in which the sulfur-containing carbonaceous fuel is mixed with H2O and an oxidant, forming a fuel/H2O/oxidant mixture. The fuel H2O/oxidant mixture is brought into contact with a catalyst composition comprising a dehydrogenation portion, an oxidation portion and a hydrodesulfurization portion, resulting in formation of a hydrogen-containing gas stream.

Abstract: An improved fuel processor for fuel cells is provided whereby the startup time of the processor is less than sixty seconds and can be as low as 30 seconds, if not less. A rapid startup time is achieved by either igniting or allowing a small mixture of air and fuel to react over and warm up the catalyst of an autothermal reformer (ATR). The ATR then produces combustible gases to be subsequently oxidized on and simultaneously warm up water-gas shift zone catalysts. After normal operating temperature has been achieved, the proportion of air included with the fuel is greatly diminished.

Abstract: A fuel processor having a dynamically controlled thermal integration mechanism and a method for dynamically controlling temperatures in a fuel processor. Such dynamic control accomplished by the use of an autothermal reformer, a steam/air superheater, water/air injectors, water gas shift reactors, heat exchangers, preferential oxidation reactors, wherein the feed/reactant streams are used as the coolant to remove heat from the reformate gas stream.

Abstract: A method of producing a H2 rich gas stream includes supplying an O2 rich gas, steam, and fuel to an inner reforming zone of a fuel processor that includes a partial oxidation catalyst and a steam reforming catalyst or a combined partial oxidation and stream reforming catalyst. The method also includes contacting the O2 rich gas, steam, and fuel with the partial oxidation catalyst and the steam reforming catalyst or the combined partial oxidation and stream reforming catalyst in the inner reforming zone to generate a hot reformate stream. The method still further includes cooling the hot reformate stream in a cooling zone to produce a cooled reformate stream. Additionally, the method includes removing sulfur-containing compounds from the cooled reformate stream by contacting the cooled reformate stream with a sulfur removal agent.

Abstract: A method of producing a H2 rich gas stream includes supplying an O2 rich gas, steam, and fuel to an inner reforming zone of a fuel processor that includes a partial oxidation catalyst and a steam reforming catalyst or a combined partial oxidation and stream reforming catalyst. The method also includes contacting the O2 rich gas, steam, and fuel with the partial oxidation catalyst and the steam reforming catalyst or the combined partial oxidation and stream reforming catalyst in the inner reforming zone to generate a hot reformate stream. The method still further includes cooling the hot reformate stream in a cooling zone to produce a cooled reformate stream. Additionally, the method includes removing sulfur-containing compounds from the cooled reformate stream by contacting the cooled reformate stream with a sulfur removal agent.

Abstract: A monolithic catalyst with micro-scale flow channels and methods of making such a monolithic catalyst are provided. The monolithic catalyst includes a plurality of thin catalyst walls. The walls have a set thickness in a range from 1 to 150 &mgr;m. The thin catalyst walls define a plurality of flow channels. A fugitive material is used to form the flow channels. The flow channels have a set width in a range from 1 to 200 &mgr;m. The flow channels are formed by an organic fugitive material, which burns off during processing. By using the thin catalyst walls and flow channels having a set width in a range from 1 to 200 &mgr;m, a reduced diffusion path length that molecules travel between the bulk gas and the active site is provided. Accelerating the mass transport thus improves the overall reaction rate, which allows processing of more reactants. Thus, the volume of the required catalyst is reduced, allowing more compact reactors.

Abstract: A dynamic, compact, lightweight fuel processor that is capable of converting carbonaceous fuels to hydrogen rich gases suitable for all types of fuel cells or chemical processing applications. The fuel processor and process are based on the autothermal hydrodesulfurizing reforming reaction, followed by clean up of byproduct sulfur-containing gases and carbon monoxide that poison the fuel cell electrocatalyst. The fuel processor uses proprietary catalysts and hardware designs that enable the conversion in an energy efficient manner while maintaining desirable performance characteristics such as rapid start-stop and fast response to load change capabilities.

Abstract: A method for reforming a sulfur-containing carbonaceous fuel in which the sulfur-containing carbonaceous fuel is mixed with H2O and an oxidant, forming a fuel/H2O/oxidant mixture. The fuel H2O/oxidant mixture is brought into contact with a catalyst composition comprising a dehydrogenation portion, an oxidation portion and a hydrodesulfurization portion, resulting in formation of a hydrogen-containing gas stream.

Abstract: A multi-part catalyst composition having a dehydrogenation portion, an oxidation portion and a hydrodesulfurization portion. The catalyst composition is suitable for reforming a sulfur-containing carbonaceous fuel.

Abstract: A method of generating a H2 rich gas from a fuel includes supplying a mixture of molecular oxygen, fuel, and water to a fuel processor, and converting the mixture of molecular oxygen, fuel, and water in the fuel processor to the H2 rich gas. The fuel has the formula CnHmOp where n has a value ranging from 1 to 20 and is the average number of carbon atoms per mole of the fuel; m has a value ranging from 2 to 42 and is the average number of hydrogen atoms per mole of the fuel; and p has a value ranging from 0 to 12 and is the average number of oxygen atoms per mole of the fuel. The molar ratio of molecular oxygen supplied to the fuel processor per mole of fuel is a value ranging from about 0.5x0 to about 1.5x0, and the value of x0 is equal to 0.312n−0.5p+0.5(&Dgr;Hf, fuel/&Dgr;Hf, water) where n and p have the values described above, &Dgr;Hf, fuel is the heat of formation of the fuel, and &Dgr;Hf, water is the heat of formation of water.

Abstract: A method of producing a H2 rich gas stream includes supplying an O2 rich gas, steam, and fuel to an inner reforming zone of a fuel processor that includes a partial oxidation catalyst and a steam reforming catalyst or a combined partial oxidation and stream reforming catalyst. The method also includes contacting the O2 rich gas, steam, and fuel with the partial oxidation catalyst and the steam reforming catalyst or the combined partial oxidation and stream reforming catalyst in the inner reforming zone to generate a hot reformate stream. The method still further includes cooling the hot reformate stream in a cooling zone to produce a cooled reformate stream. Additionally, the method includes removing sulfur-containing compounds from the cooled reformate stream by contacting the cooled reformate stream with a sulfur removal agent.

Abstract: A monolithic catalyst with micro-scale flow channels and methods of making such a monolithic catalyst are provided. The monolithic catalyst includes a plurality of thin catalyst walls. The walls have a set thickness in a range from 1 to 150 &mgr;m. The thin catalyst walls define a plurality of flow channels. A fugitive material is used to form the flow channels. The flow channels have a set width in a range from 1 to 200 &mgr;m. A flexible strip that includes a layer of catalyst material and a fugitive layer forms the monolithic catalyst. This flexibility allows the strips to be formed into selected shapes as needed for a particular reactor design. For example, strips can be rolled into a spiral cylinder or folded into a planar stack. The flow channels are formed by an organic fugitive material, which burns off during processing.