Abstract: A fuel processor for rapid start and operational control. The fuel processor includes a reformer, a shift reactor, and a preferential oxidation reactor for deriving hydrogen for use in creating electricity in a plurality of H2—O2 fuel cells. A heating and cooling mechanism is coupled to at least the shift reactor for controlling the critical temperature operation of the shift reactor without the need for a separate cooling loop. This heating and cooling mechanism produces or removes thermal energy as a product of the temperature of the combustion of air and fuel. Anode effluent and cathode effluent or air are used to control the temperature output of the heating mechanism. A vaporizer is provided that heats the PrOx reactor to operating temperature.

Abstract: An improved fuel processor thermal management system for use with a fuel cell is disclosed. The process includes supplying an air stream and a fuel stream into a auto thermal reactor (ATR) and forming reformate gas therein. Then, preferentially oxidizing the reformate gas and the air stream in the preferential oxidizer reactor (PrOx). The temperature of the preferential oxidizer reaction is controlled with a water stream by vaporizing the water stream to form a first portion of vaporized water. Then, reacting the air stream with the reformate gas exiting the PrOx is reached in a fuel cell to form an anode exhaust stream which is subsequently combined with the air stream to heat the water stream to form a second portion of vaporized water. The first portion of vaporized water and the second portion of vaporized water form a steam fluid.

Abstract: Apparatus and method for mixing fuel and an oxidant for use in an autothermal reformer that provides hydrogen to a fuel cell. The apparatus includes a mixing vessel (10) , a first inlet (4) to the mixing vessel for movement of gaseous fuel or oxidant therethrough, a second inlet for movement of gaseous fuel or oxidant therethrough, and an exit (60) from the vessel adjacent the autothermal reformer. The discharge ends of the inlets are spaced apart from each other and from the exit which is near a POX reactor (61) that combusts the mixture of fuel and oxidant exiting from the mixing vessel. The first inlet is comprised of a plate (26) with a plurality of tubes (24) extending therefrom through which fuel or oxidant passes.

Abstract: A fuel processor for a fuel cell includes a thermal start device, a mixing region and a temperature control element. The temperature control element is located between the thermal start device and the mixing region. The temperature control element reduces temperature increase in the mixing region during thermal startup. A flame arrestor is connected to the mixing region. A primary reactor is connected to the flame arrestor. The transient temperature control element has a body defining an inlet and an outlet. A plurality of bores are formed in the body.

Abstract: The present invention relates to an electrochemical cell having The separator assembly that comprises a fluid distribution means comprising wicking material on the cathode side of a membrane electrode assembly (MEA). The wicking material transports liquids internally within the fuel cell; promotes humidification of the membrane; and provides a self-regulating cooling system for the fuel cell. The wicking material further forms gas flow channels for introducing gases to and from the MEA. Other preferred aspects of the present invention include methods of cooling the fuel cell by evaporation and/or vaporization at the cathode side.

Abstract: A primary reactor for a fuel processor system that employs steam and air to convert a liquid hydrocarbon fuel into a hydrogen-rich gas stream. The liquid fuel and an air-steam mixture are mixed in a mixing region within the reactor. The fuel mixture is then directed through an electrically heated catalyst region that heats the mixture to the operation temperature of a light-off catalyst at system start-up. The heated fuel mixture is then directed through a light-off catalyst monolith where the hydrocarbon fuel is dissociated. Once the fuel mixture is heated to the operating temperature of the light-off catalyst, the electrically heated catalyst region is turned off because the exothermic reaction in the light-off catalyst monolith generates the heat necessary to sustain the catalytic reaction.

Abstract: The present invention relates to a fuel processing unit in an electrochemical fuel cell power plant, and more specifically to a preheater combustor that forms byproduct compounds that may destroy downstream catalytic reactors for fuel reforming. The present invention includes a retention material that collects the byproduct compounds prior to entry into the downstream reactors. The retention material may be comprised of at least one active compound and a support structure, preferably having a porous body to facilitate tortuous fluid flow. Further aspects of the invention may include an electrical charging device for use with the retention device material that enhances collection of byproduct compounds. The present invention also includes a method of operation for start-up incorporating a retention material.

Abstract: The present invention provides a combustor for a fuel processor which integrates a burner and a catalyst. The burner is utilized to quickly heat the catalyst to a light-off temperature to prepare it for normal operation. The heated catalyst is then used to react anode exhaust with air or cathode exhaust under normal operation.

Abstract: A flow translocator disposed within a conduit for transferring and separating laminar fluid flow during translocation of the fluid core to the outer perimeter of the conduit and the outer perimeter flow to the center of the conduit. The flow translocator includes a disk disposed transverse the length of a conduit and having an outer profile conforming to the inner profile of a conduit to form a sealed fit. Arrays of slots extend about the disk for simultaneously directing the fluid core to the inner profile of a conduit and the outer perimeter flow toward the fluid core. The slots are staggered to maintain separation of the fluid core and the outer perimeter fluid during translocation.

Abstract: A fuel cell system including a fuel reforming processor having a catalyst therein constructed and arranged to produce a reformate stream including hydrogen and carbon monoxide, a water gas shift reactor downstream of the fuel reforming processor and wherein the water gas shift reactor includes a catalyst therein constructed and arranged to reduce the amount of carbon monoxide in the reformate stream, a preferential oxidation reactor downstream of the water gas shift reactor and wherein the preferential oxidation reactor includes a catalyst therein constructed and arranged to preferentially oxidize carbon monoxide into carbon dioxide and to produce a hydrogen-rich stream, and a fuel cell stack downstream of the preferential oxidation reactor constructed and arranged to produce electricity from the hydrogen-rich stream, a first direct water vaporizing combustor constructed and arranged to combust fuel producing a high-temperature fuel combustion byproducts exhaust and to produce steam from water sprayed into th

Abstract: A fuel processor system capable of circulating fuel processor system gases, such as reformate, anode exhaust, and/or combustor exhaust, through the fuel processor to provide a number of distinct advantages. The fuel processor system having a plurality of fuel cells discharging an H2-containing anode effluent and an O2-containing cathode effluent. A fuel processor is also provided for converting a hydrogen-containing fuel to H2-containing reformate for fueling the plurality of fuel cells. A catalytic combustor is positioned in series downstream from the plurality of fuel cells and a vaporizer reactor is coupled to the catalytic combustor. A bypass passage is finally provided that interconnects an outlet of at least one of the group consisting of the fuel processor, the plurality of fuel cells, the catalytic combustor, and the vaporizer reactor to the inlet of the fuel processor. The bypass passage is operable to circulate a fuel processor system gas to the inlet of the fuel processor.

Abstract: Apparatus and method for mixing fuel and an oxidant for use in an autothermal reformer that provides hydrogen to a fuel cell. The apparatus includes a mixing vessel (10), a first inlet (4) to the mixing vessel for movement of gaseous fuel or oxidant therethrough, a second inlet for movement of gaseous fuel or oxidant therethrough, and an exit (60) from the vessel adjacent the autothermal reformer. The discharge ends of the inlets are spaced apart from each other and from the exit which is near a POX reactor (61) that combusts the mixture of fuel and oxidant exiting from the mixing vessel. The first inlet is comprised of a plate (26) with a plurality of tubes (24) extending therefrom through which fuel or oxidant passes.

Abstract: The present invention provides a combustor for a fuel processor which integrates a burner and a catalyst. The burner is utilized to quickly heat the catalyst to a light-off temperature to prepare it for normal operation. The heated catalyst is then used to react anode exhaust with air or cathode exhaust under normal operation.

Abstract: An improved fuel processor thermal management system for use with a fuel cell is disclosed. The process includes supplying an air stream and a fuel stream into a auto thermal reactor (ATR) and forming reformate gas therein. Then, preferentially oxidizing the reformate gas and the air stream in the preferential oxidizer reactor (PrOx). The temperature of the preferential oxidizer reaction is controlled with a water stream by vaporizing the water stream to form a first portion of vaporized water. Then, reacting the air stream with the reformate gas exiting the PrOx is reached in a fuel cell to form an anode exhaust stream which is subsequently combined with the air stream to heat the water stream to form a second portion of vaporized water. The first portion of vaporized water and the second portion of vaporized water form a steam fluid.

Abstract: A fuel processor for rapid start and operational control. The fuel processor includes a reformer, a shift reactor, and a preferential oxidation reactor for deriving hydrogen for use in creating electricity in a plurality of H2—O2 fuel cells. A heating and cooling mechanism is coupled to at least the shift reactor for controlling the critical temperature operation of the shift reactor without the need for a separate cooling loop. This heating and cooling mechanism produces or removes thermal energy as a product of the temperature of the combustion of air and fuel. Anode effluent and cathode effluent or air are used to control the temperature output of the heating mechanism. A vaporizer is provided that heats the PrOx reactor to operating temperature.

Abstract: A fuel processor for rapidly achieving operating temperature during startup. The fuel processor includes a reformer, a shift reactor, and a preferential oxidation reactor is provided for deriving hydrogen for use in creating electricity in a plurality of fuel cells. A first combustion heater system is coupled to at least one of the reformer, the shift reactor, and the preferential oxidation reactor to preheat the component during a rapid startup sequence. That is, the first combustion heater system is operable to produce thermal energy as a product of the combustion of air and fuel in the form of a first heated exhaust stream. This first heated exhaust stream is then used to heat the component directly or by using a heat exchanger type system. The first heated exhaust stream is also used by a second combustion device as a source of oxygen or diluent.

Abstract: A reactor system including a reactor housing having an inlet portion defined at one end of the housing and having a discharge opening formed in the housing at an opposite end. An air intake charge line is connected to the housing for charging air into the inlet portion. A steam charge line is connected to the housing for charging steam into the inlet portion. A fuel injector is positioned in the housing for injecting fuel into the stream of air and steam flowing through the housing. A fuel charge line is connected to the fuel injector for charging a carbon-based fuel into the injector. A catalyst bed is carried in the housing and positioned downstream of the fuel injector and at least a portion of the catalyst bed includes a catalyst for promoting the reformation of the carbon-based fuel to produce hydrogen. An auto-ignition and carbon-suppression foam is carried in the housing and positioned between the catalyst bed and the fuel injector.

Abstract: Method of operating an autothermal reformer (ATR) to produce a high temperature reformate including preheating steam and air inputs to the ATR with heat from the reformate. The steam is heated by the reformate, and the air is then heated by the steam. There is no direct heat exchange between the reformate and the air. In the heat exchangers effecting the heat transfer, the steam is kept at a higher pressure that both the reformate and the air.

Abstract: A flow translocator disposed within a conduit for transferring and separating laminar fluid flow during translocation of the fluid core to the outer perimeter of the conduit and the outer perimeter flow to the center of the conduit. The flow translocator includes a disk disposed transverse the length of a conduit and having an outer profile conforming to the inner profile of a conduit to form a sealed fit. Arrays of slots extend about the disk for simultaneously directing the fluid core to the inner profile of a conduit and the outer perimeter flow toward the fluid core. The slots are staggered to maintain separation of the fluid core and the outer perimeter fluid during translocation.

Abstract: A fuel processor for a fuel cell includes a thermal start device, a mixing region and a temperature control element. The temperature control element is located between the thermal start device and the mixing region. The temperature control element reduces temperature increase in the mixing region during thermal startup. A flame arrestor is connected to the mixing region. A primary reactor is connected to the flame arrestor. The transient temperature control element has a body defining an inlet and an outlet. A plurality of bores are formed in the body.