Condenser/separator and method

A cathode exhaust gas condenser for use in a fuel cell system for separating a cathode exhaust into a condensed liquid and a non-condensed gas comprising:

• a vertical inlet manifold to receive the cathode exhaust;
• a vertical outlet manifold;
• a cathode exhaust flow path fluidly connected to the inlet manifold and the outlet manifold to direct a gas flow from the inlet manifold to the outlet manifold in heat exchange relation to a cooling fluid flow;
• a liquid flow path fluidly connected to the inlet manifold and the outlet manifold to direct a liquid flow in multiple passes between the inlet manifold and the outlet manifold in heat exchange relation to the cooling fluid flow;
• a gas outlet fluidly connected to the outlet manifold to permit the non-condensed gas to exit the condenser;
• and
• a liquid outlet fluidly connected to one of the manifolds to permit the condensed liquid to exit the condenser.

A condenser for separating a fluid mixture into a condensed liquid and a non-condensed gas comprising:

• a vertical inlet manifold to receive the gas mixture and having an upper portion and a lower portion;
• a vertical outlet manifold to receive the condensed liquid and the non-condensed gas and having an upper portion and a lower portion;
• a liquid level separating the upper portion from the lower portion in each of the manifolds;
• a gas flow path fluidly connected to the inlet manifold and the outlet manifold to direct a gas flow from the inlet manifold to the outlet manifold in heat exchange relation to a cooling fluid flow;
• a liquid flow path fluidly connected to the inlet manifold and the outlet manifold to direct a liquid flow from the inlet manifold to the outlet manifold in heat exchange relation to the cooling fluid flow;
• a gas outlet fluidly connected to the gas flow path to permit the non-condensed gas to exit the condenser;
• and
• a liquid outlet fluidly connected to the liquid flow path to permit the condensed liquid to exit the condenser.

A cathode exhaust condenser for use in a fuel cell system for separating a cathode exhaust into a condensed liquid and a non-condensed gas comprising:

• a vertical inlet manifold to receive the cathode exhaust and having an upper portion and a lower portion;
• a vertical outlet manifold to receive the condensed liquid and the non-condensed gas and having an upper portion and a lower portion;
• a liquid level separating the upper portion from the lower portion in each of the manifolds;
• a gas flow path fluidly connected to the inlet manifold and the outlet manifold to direct a gas flow from the inlet manifold to the outlet manifold in heat exchange relation to a cooling fluid flow;
• a liquid flow path fluidly connected to the inlet manifold and the outlet manifold to direct a liquid flow from the inlet manifold to the outlet manifold in heat exchange relation to the cooling fluid flow;
• a gas outlet fluidly connected to the gas flow path to permit the non-condensed gas to exit the condenser;
• and
• a liquid outlet fluidly connected to the liquid flow path to permit the condensed liquid to exit the condenser.

A method for separating a fluid mixture into a condensed liquid and a non-condensed gas in a condenser, the method comprising the steps of:

• flowing the fluid mixture into an inlet manifold;
• separating the fluid mixture into a gas flow and a liquid flow in the inlet manifold;
• cooling the liquid flow by flowing the liquid flow through a liquid flow path to an outlet manifold;
• condensing at least a portion of the gas flow into condensed liquid by flowing the gas flow through a gas flow path to the outlet manifold;
• again separating condensed liquid from non-condensed gas in the outlet manifold;
• directing the non-condensed gas out of the condenser through a gas outlet;
• and
• directing the condensed liquid out of the condenser through a liquid outlet.