Abstract: Hydrogen-producing fuel processing systems, hydrogen purification membranes, hydrogen purification devices, and fuel processing and fuel cell systems that include hydrogen purification devices. In some embodiments, the fuel processing systems and the hydrogen purification membranes include a metal membrane, which is at least substantially comprised of palladium or a palladium alloy. In some embodiments, the membrane contains trace amounts of carbon, silicon, and/or oxygen. In some embodiments, the membranes form part of a hydrogen purification device that includes an enclosure containing a separation assembly, which is adapted to receive a mixed gas stream containing hydrogen gas and to produce a stream that contains pure or at least substantially pure hydrogen gas therefrom. In some embodiments, the membrane(s) and/or purification device forms a portion of a fuel processor, and in some embodiments, the membrane(s) and/or purification device forms a portion of a fuel processing or fuel cell system.

Abstract: The invented system includes a fuel-cell system comprising a fuel cell that produces electrical power from air (oxygen) and hydrogen, and a fuel processor that produces hydrogen from a variety of feedstocks. One such fuel processor is a steam reformer which produces purified hydrogen from a carbon-containing feedstock and water. In the invented system, various mechanisms for implementing the cold start-up of the fuel processor are disclosed, as well as mechanisms for optimizing and/or harvesting the heat and water requirements of the system and/or maintaining the purity of the process water used in the system.

Abstract: Hydrogen-producing fuel processing systems, hydrogen purification membranes, hydrogen purification devices, and fuel processing and fuel cell systems that include hydrogen purification devices. In some embodiments, the fuel processing systems and the hydrogen purification membranes include a metal membrane, which is at least substantially comprised of palladium or a palladium alloy. In some embodiments, the membrane contains trace amounts of carbon, silicon, and/or oxygen. In some embodiments, the membranes form part of a hydrogen purification device that includes an enclosure containing a separation assembly, which is adapted to receive a mixed gas stream containing hydrogen gas and to produce a stream that contains pure or at least substantially pure hydrogen gas therefrom. In some embodiments, the membrane(s) and/or purification device forms a portion of a fuel processor, and in some embodiments, the membrane(s) and/or purification device forms a portion of a fuel processing or fuel cell system.

Abstract: A system and method for preventing damage to a fuel cell stack resulting from impurities in a hydrogen stream delivered thereto. In some embodiments, the hydrogen stream is a product hydrogen stream from a fuel processor. In some embodiments, the impurities may result from a failure or malfunction in a separation region adapted to remove impurities in the hydrogen stream. The system and method include detecting the concentration of at least one component of the hydrogen stream and isolating the fuel cell stack should this concentration exceed an acceptable threshold level. In some embodiments, the system or method are adapted to detect the concentration of a component that itself is not harmful to the fuel cell stack, or which is not harmful in an associated threshold concentration. In some embodiments, the detected composition is at least one of water, methane, and carbon dioxide.

Abstract: Hydrogen purification devices, components thereof, and fuel processors, fuel processing systems, and fuel cell systems containing the same. The hydrogen purification devices include an enclosure that contains a separation assembly adapted to receive a mixed gas stream containing hydrogen gas and to produce a stream that contains pure or at least substantially pure hydrogen gas therefrom. In some embodiments, the separation assembly includes at least one hydrogen-permeable and/or hydrogen-selective membrane. In some embodiments, the fuel processors, fuel processing systems, and/or fuel cell systems include at least one modular, or cartridge-based component. In some embodiments, the hydrogen purification device is, and/or includes, a modular, or cartridge-based, component. In some embodiments, the hydrogen purification device includes components that are formed from materials having the same or similar coefficients of thermal expansion.

Abstract: A feedstock mixing apparatus for fuel processing systems, and fuel processing and fuel cell systems incorporating the same. A fuel processing system according to the present invention includes one or more fuel processors adapted to produce a product hydrogen stream from a feed stream containing water and a carbon-containing feedstock. The fuel processing system further includes a feedstock delivery system adapted to mix the components of the feed stream at a determined mix ratio and to deliver this feed stream to the fuel processor(s). The fuel processing system may also include one or more fuel cell stacks that are adapted to produce an electric current from the product hydrogen stream produced by the fuel processing system. When the fuel processing system includes at least one fuel cell stack, it may be referred to as a fuel cell system.

Abstract: Fuel processing systems, which contain a fuel processor, and feedstock treatment systems for use in the same. The fuel processor is configured to produce a hydrogen, or hydrogen-rich, stream from a feed stream, which may include, for example, at least one carbon-containing feedstock and/or water. At least a portion of the feed stream is a vaporized feed stream. The fuel processing system further includes a treatment region configured to remove solids from at least the vaporized component of the feed stream prior to production of hydrogen gas from the feed stream. In some embodiments, a common housing at least substantially encloses one or more regions of the fuel processing system, and in some embodiments one or more of those regions are accessible from external the common housing without disassembling that housing.

Abstract: Hydrogen purification membranes, hydrogen purification devices, and fuel processing and fuel cell systems that include hydrogen purification devices. The hydrogen purification membranes include a metal membrane, which is at least substantially comprised of palladium or a palladium alloy. In some embodiments, the membrane contains trace amounts of carbon, silicon, and/or oxygen. In some embodiments, the membranes form part of a hydrogen purification device that includes an enclosure containing a separation assembly, which is adapted to receive a mixed gas stream containing hydrogen gas and to produce a stream that contains pure or at least substantially pure hydrogen gas therefrom. In some embodiments, the membrane(s) and/or purification device forms a portion of a fuel processor, and in some embodiments, the membrane(s) and/or purification device forms a portion of a fuel processing or fuel cell system.

Abstract: The invented system includes a fuel-cell system comprising a fuel cell that produces electrical power from air (oxygen) and hydrogen, and a fuel processor that produces hydrogen from a variety of feedstocks. One such fuel processor is a steam reformer which produces purified hydrogen from a carbon-containing feedstock and water. In the invented system, various mechanisms for implementing the cold start-up of the fuel processor are disclosed, as well as mechanisms for optimizing and/or harvesting the heat and water requirements of the system and/or maintaining the purity of the process water used in the system.

Abstract: Systems and methods for recovering thermal energy from a fuel processing system comprising a fuel processor and a fuel cell stack in communication with a household that is adapted to apply at least electrical loads, and optionally electrical and thermal loads, to the fuel processing system. The systems further include a thermal energy recovery system that is adapted to recover thermal energy from the fuel processing system and which includes a plurality of thermal energy reservoirs. The recovery system includes a delivery system that is adapted to selectively deliver heat exchange fluid from at least one of the plurality of thermal energy reservoirs into thermal communication with the fuel processing system to recover thermal energy therefrom. In some embodiments, at least one of the thermal energy reservoirs forms at least a portion of a potable hot water supply for the household.

Abstract: A control system and method for a fuel processing system. The control system automates the operation of a fuel processing system by monitoring operating parameters and automatically controlling the operation of the system responsive to the monitored parameters, predefined subroutines and/or user inputs.

Abstract: A system and method for preventing damage to a fuel cell stack resulting from impurities in the product stream from a fuel processor, such as may occur should the separation region of the fuel processor fail. The system and method include detecting the concentration of at least one component of the product stream and isolating the fuel cell stack should this concentration exceed an acceptable threshold level. In some embodiments, the system or method are adapted to detect the concentration of a component that itself is not harmful to the fuel cell stack, or which is not harmful in an associated threshold concentration. In some embodiments, the detected composition is at least one of water, methane, and carbon dioxide.

Abstract: A mould for injection welding a junction between a thermoplastics sleeve and a cable having an outer sheath of thermoplastics material, which mould comprises three parts: one part is heat-conductive with a bore for receiving the end of the cable; one part is heat-insulating with a bore for receiving the sleeve, and the final part is heat-conductive with an enlarged bore for surrounding the actual joint. When the mould is assembled, this final part receives the ends, at least, of the other two parts and prevents relative axial and radial movement between the mould parts.