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 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 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: In one aspect, the present invention provides a method for operating a fuel cell system. The system comprises a reactor having one or more catalytic beds and is fed a hydrocarbon fuel along with air and steam. Where more than one catalytic bed is present, such catalytic beds are preferably arranged sequentially such that the outlet from one bed enters the inlet of the next bed. The catalytic beds are the regions where reactions among the hydrocarbon, air, and steam are catalyzed within the reactor. The method comprises supplying a stream of a fuel and air mixture to the reactor which is lean. The mixture is lean in that it has an excess amount of oxygen relative to the stoichiometric amount required for reaction with the fuel. The reactions occurring with the lean mixture heat the reactor. When there is more than one catalytic bed, the hot gases generated from one catalytic bed can be used to heat other catalytic beds.

Abstract: A method for controlling the power and temperature and fuel source of a combustor in a fuel cell apparatus to supply heat to a fuel processor where the combustor has dual fuel inlet streams including a first fuel stream, and a second fuel stream of anode effluent from the fuel cell and reformate from the fuel processor. In all operating modes, an enthalpy balance is determined by regulating the amount of the first and/or second fuel streams and the quantity of the first air flow stream to support fuel processor power requirements.

Abstract: An apparatus removes carbon monoxide (CO) from a hydrogen-rich gas stream in a hydrogen fuel cell system. CO fouls costly catalytic particles in the membrane electrode assemblies of proton exchange membrane (PEM) fuel cells. A vessel houses a carbon monoxide adsorbent. The vessel may be a rotating pressure swing adsorber. A water gas shift reactor is upstream of the rotating pressure swing adsorber. The water gas shift reactor may include a second adsorbent adapted to adsorb carbon monoxide at low temperatures and to desorb carbon monoxide at high temperatures. The apparatus advantageously eliminates the use of a preferential oxidation (PROX) reactor, by providing an apparatus which incorporates CO adsorption in the place of the PROX reactor. This cleans up carbon monoxide without hydrogen consumption and the concomitant, undesirable excess low grade heat generation. The present invention reduces start-up duration, and improves overall fuel processor efficiency during normal operation.

Abstract: A burner type catalytic converter heater composed of an air intake housing having a peripheral mounting flange for universal mounting to an exhaust system upstream of the catalytic converter. A nozzle body is provided having a central portion whereat an orifice delivers atomized fuel and an annular flange portion which interfaces with the air intake housing to define an air intake chamber on an upstream side thereof. A cylindrical combustion chamber housing is provided and a single-stage vortex body is connected to one end of the combustion chamber housing, wherein vanes of the vortex body adjoin a downstream side of the annular flange portion.

Abstract: A valve for an automotive vehicle emission system is provided which includes a valve housing with an inlet communicating the valve housing with an air pump; an outlet fluidly communicating the valve with a catalytic converter, the outlet having a check valve preventing flow from an engine exhaust conduit through the valve to the air pump; an upper diaphragm in the valve housing creating a first chamber in the housing which is fluidly exposed to the inlet; a lower diaphragm in the housing creating a second chamber between itself and the first diaphragm, the lower diaphragm forming a third chamber between itself and the housing generally opposite the first chamber; a sealing wall located within the housing separating the second chamber from the inlet, the sealing wall having a surface forming a valve seat with the lower diaphragm, dividing the inlet from the second chamber; a spring urging the lower diaphragm toward the first chamber; and a valve stem connecting the upper and lower diaphragms wherein the air pr

Abstract: An electronically controlled fuel system for use with a continuous, non-cyclical process has a fuel manifold to which pressurized fuel from a source is supplied and through which the fuel is metered, to an end use combustor, by a periodically energizable pulse-width modulated, solenoid actuated valve. The pulsed fuel output of the valve is exposed to an accumulator which operates on the output to reduce the amplitude of the pulsations effectively integrating them out of the fuel flow, resulting in a substantially continuous supply of fuel. A purge system may be integrated into the fuel manifold and has a second solenoid actuated valve member which is operable, upon fuel system shut-down, to direct pressurized air through the fuel system to remove excess fuel.

Abstract: Control of a fuel rate and an air rate delivered to an exhaust gas heater over successive control periods by determining and periodically updating a desired heater air quantity and a desired heater air/fuel ratio, by commanding an air rate in accord with the desired heater air quantity, by adjusting the commanded air rate in accord with a sensed actual air rate, and by commanding a fuel quantity in accord with the desired heater air/fuel ratio and the sensed actual air rate or the desired heater air quantity. A quantity of excess fuel is purged from the system at the end of a control period and provided in usable form to the engine. Compensation for fuel residue in the system is made at the start of subsequent control periods.

Abstract: Control of a fuel quantity and an air quantity delivered to an exhaust gas heater is provided by determining a desired heater air quantity and a desired heater air/fuel ratio both of which may vary over multiple control states, by commanding an air rate in accord with the desired heater air quantity, by adjusting the commanded air quantity in accord with a sensed actual air quantity, and by commanding a fuel quantity in accord with the desired heater air/fuel ratio and either the desired heater air quantity or the sensed actual air quantity.

Abstract: A burner for heating an exhaust gas stream is disclosed having a combustor head with a fuel/air charge preparation apparatus comprising a fuel nozzle and dual vortex atomizer. The charge preparation apparatus is mounted on one side of a base member or partitioning member having an outlet through which the atomized fuel and air pass to a combustor chamber defined by a combustor tube fixed to a second side of the partition. The combustor tube has an ignitor and outlets for the burning fuel/air mixture. The outlets have flow directing louvers which function to direct the output in a predetermined direction to optimize mixing of the burner output with an exhaust gas stream. The combustor head is mounted through an opening in a housing which positions the combustor tube outlets in the exhaust stream.