Steam reforming fuel processor

A steam reforming fuel processor, comprising:

• a base including a mount for a burner assembly;
• an insulating shell mounted on the base and defining with the base an internal compartment;
• a burner assembly that includes an ignition region and which is adapted to introduce a heated exhaust stream into a combustion region that is generally centrally located within the shell, wherein the combustion region includes a first portion that is generally proximate the ignition region and a second portion that is distal the ignition region;
• a vaporization region adapted to receive a reforming feed stream comprising water and at least one carbon-containing feedstock and to form a vaporized feed stream therefrom, wherein the vaporization region extends radially around the combustion region;
• a reforming region containing a plurality of vertically oriented reforming catalyst beds, wherein each reforming catalyst bed includes an inlet region adapted to receive the vaporized feed stream and to produce a reformate stream containing hydrogen gas and other gases therefrom, and an outlet region adapted to exhaust the reformate stream, wherein the plurality of reforming catalyst beds are generally symmetrically and radially spaced around the vaporization region and the combustion region;
• an annular distribution manifold adapted to receive the reforming feed stream and to distribute the reforming feed stream to the inlet regions of the reforming catalyst beds, wherein the annular distribution manifold includes a central opening through which at least one of a portion of the burner assembly extends or through which the heated exhaust stream flows;
• an annular collection manifold adapted to receive the reformate stream from the outlet regions of the reforming catalyst beds, wherein the collection manifold is in fluid communication with a separation region, wherein the annular collection manifold includes a central opening through which at least one of a portion of the burner assembly extends or through which the heated exhaust stream flows;
• a separation region proximate the second portion of the combustion region and adapted to receive the reformate stream and to produce a hydrogen-rich stream containing at least substantially pure hydrogen gas and a byproduct stream containing at least a substantial portion of the other gases, wherein the separation region includes an enclosure containing at least one hydrogen-selective membrane and into which the reformate stream is introduced, with the hydrogen-rich stream being formed from a portion of the reformate stream that passes through the at least one hydrogen-selective membrane and the byproduct stream being formed from a portion of the reformate stream that does not pass through the at least one hydrogen-selective membrane, wherein the at least one hydrogen-selective membrane extends generally transverse to the axis extending at least generally parallel to the plurality of reforming catalyst beds;
• and
• at least one methanation catalyst bed containing a methanation catalyst and adapted to receive the hydrogen-rich stream and to reduce the concentration of any carbon monoxide present in the hydrogen-rich stream.