Combustion heater and fuel processor utilizing ceramic technology

A method of forming a chemical combustion heater comprising the steps of:

• providing a ceramic material;
• defining therein the ceramic material, at least one ceramic cavity, the at least one ceramic cavity having a geometric surface area;
• firing the ceramic material to form a ceramic carrier structure having the at least one ceramic cavity defined therein;
• depositing a catalyst material within the at least one ceramic cavity, the catalyst characterized as providing for complete air oxidation of an input fuel and the generation of heat.

A fuel processor comprising:

• a thermally conductive ceramic carrier defining a fuel reformer, the fuel reformer including a reaction zone including a reforming catalyst and an integrated chemical combustion heater thermally coupled to the reaction zone, wherein the chemical combustion heater has defined therein a plurality of thin ceramic layers assembled and sintered to provide for at least one ceramic cavity having a geometric surface area and a catalyst material formed within the at least one ceramic cavity arranged to air oxidize an input fuel to produce heat;
• an inlet channel for liquid fuel;
• an outlet channel for hydrogen enriched gas;
• and
• an integrated fuel cell, including an anode in microfluidic communication with the outlet channel.