Abstract: A fuel processing system is provided for reforming a hydrocarbon fuel. This fuel processing system utilizes a membrane separator to separate the hydrogen from the reformate stream. A CO-reduction and cleanup system works with the membrane separator to increase the production of hydrogen.

Abstract: A fuel processing system is provided for reforming a hydrocarbon fuel. This fuel processing system utilizes a membrane separator to separate the hydrogen from the reformate stream. A CO-reduction and cleanup system works with the membrane separator to increase the production of hydrogen.

Abstract: A customized flow path substrate is provided that comprises fins of varying material and geometry within a catalyst bed of fuel processing reactors. The fins are preferably secured to a core and are assembled by winding the fins around the core and placing the wound fins and the core into a tube to form a tube assembly, which is positioned within the fuel processing reactor. Either one or a plurality of fins may be secured to an individual core, wherein either or both the material and the geometry are varied to customize the flow path and to provide for efficient mixing of gases and to break boundary layer between bulk gas stream and substrate for enhancing mass transfer rate. In addition, the fins are coated with a catalyst material either prior to assembly in one form or after assembly within the tube in another form of the present invention.