Compact devices for generating pure hydrogen

A hydrogen generator comprising:

• a hydrogen membrane reactor, wherein the hydrogen membrane reactor comprises a separation plate and two chambers on either side of the separation plate, one chamber defining a reaction chamber containing a reforming catalyst coated to a porous metal substrate, and the other chamber defining a combustion chamber containing a combustion catalyst coated to a porous metal substrate,
• an end plate to close the combustion chamber on the side opposing the separation plate,
• a membrane assembly containing a membrane and a membrane support sub-assembly, to close the reaction chamber on the side opposing the separation plate, wherein a membrane surface not in contact with the support sub-assembly is situated close to the reaction catalyst substrate but separated from the catalyst substrate, and
• a hydrogen plenum located on the other side of the membrane assembly to provide a plenum for collecting hydrogen.

A membrane assembly to be joined to a reaction chamber of a hydrogen generator having a hydrogen plenum to form a leak tight reactor sub-assembly, the membrane assembly comprising:

• a membrane;
• and
• a membrane support comprising a sintered porous metal
• wherein the membrane is sealed between a first surface of the membrane support and a frame, and wherein a second surface of the membrane support is connected to the hydrogen plenum.

A hydrogen generator comprising:

• a hydrogen membrane reactor having a combustion chamber in a fluid connection with and a heat exchange relationship with a reaction chamber,
• a feed pre-treatment chamber in a heat exchange relationship with the combustion chamber and in fluid connection with the reaction chamber,
• a fuel supply;
• a reaction fuel supply line for transporting fuel from the fuel supply to the feed pre-treatment chamber;
• a feed supply line for transporting treated fuel from the pre-treatment chamber to the reaction chamber,
• an air supply;
• an air supply line for transporting oxygen from the air supply to the combustion chamber;
• a combustion fuel supply line for transporting fuel from the fuel supply to the combustion chamber;
• a tail gas supply line for transporting tail gases from the reaction chamber;
• a combustion by-product line for transporting combustion by-products from the combustion chamber;
• and
• a reaction product line for transporting hydrogen from the reaction chamber.

A hydrogen generator comprising:

• a hydrogen membrane reactor, wherein the hydrogen membrane reactor comprises a separation plate and two chambers on either side of the separation plate, one chamber defining a reaction chamber containing a reaction catalyst coated to a porous metal substrate, and the other chamber defining a combustion chamber containing a combustion catalyst coated to a porous metal substrate,
• an end plate to close the combustion chamber on the side opposing the separation plate,
• a pre-treatment chamber bound by the combustion chamber on one side and a bottom plate on the other side and containing a reaction catalyst coated to a porous metal substrate, the bottom plate containing a winding of metal tubing on an outer surface to facilitate vaporization of water to steam,
• a membrane assembly containing a membrane and a membrane support sub-assembly, to close the reaction chamber on the side opposing the separation plate, wherein a membrane surface not in contact with the support sub-assembly is situated close to the catalyst substrate but separated from the catalyst substrate, and
• a hydrogen plenum located on the other side of the membrane assembly to provide a plenum for collecting hydrogen.

A hydrogen generator comprising:

• a hydrogen membrane reactor having a combustion chamber that is sandwiched between a first reaction chamber and a second reaction chamber wherein the combustion chamber is in a fluid connection with and in a heat exchange relationship with the first and second reaction chamber,
• an internal connector connecting the two first and second reaction chamber wherein the fluid exiting the first reaction chamber flows into the second reaction chamber,
• a fuel supply;
• a reaction fuel supply line for transporting fuel from the fuel supply to the first reaction chamber;
• an air supply;
• an air supply line for transporting oxygen from the air supply to the combustion chamber;
• a combustion fuel supply line for transporting fuel from the fuel supply to the combustion chamber;
• a tail gas supply line for transporting tail gases from the second reaction chamber;
• a combustion by-product line for transporting combustion by-products from the combustion chamber;
• and
• a reaction product line for transporting hydrogen from the first and second reaction chamber.

A membrane assembly comprising a membrane support sub-assembly and a membrane, wherein

• the membrane support sub-assembly comprises a sintered porous metal sealed to a perforated metal plate,
• a gasket is disposed between a frame and the membrane,
• the membrane is sealed between the first surface of the support sub-assembly and the frame,
• and the second surface of the support sub-assembly is welded or brazed to the hydrogen plenum to form the membrane assembly.

A hydrogen generator comprising:

• a hydrogen membrane reactor having a combustion chamber that is sandwiched between two a first reaction chamber and a second reaction chamber wherein the combustion chamber is in a fluid connection with and in a heat exchange relationship with the first and second reaction chambers,
• a fuel supply;
• a reaction fuel supply line for transporting fuel from the fuel supply to the reaction chambers;
• an air supply;
• an air supply line for transporting oxygen from the oxygen air supply to the combustion chamber;
• a combustion fuel supply line for transporting fuel from the fuel supply to the combustion chamber;
• a tail gas supply line for transporting tail gases from the reaction chambers;
• a combustion by-product line for transporting combustion by-products from the combustion chamber;
• and
• a reaction product line for transporting hydrogen from the reaction chambers.

A method to generate hydrogen from a reaction fuel, the method comprising:

• providing a hydrogen membrane reactor having a combustion chamber in fluid connection with and heat exchange relationship with a reaction chamber,
• providing a reaction fuel supply,
• transporting the reaction fuel from the reaction fuel supply to the reaction chamber through a first supply line;
• providing an air supply;
• transporting oxygen from the air supply to the combustion chamber through an air supply line;
• providing a combustion fuel supply;
• transporting the combustion fuel from the combustion fuel supply to the combustion chamber through a combustion fuel supply line;
• reacting the combustion fuel in the combustion chamber to provide heat and combustion by-products;
• reacting the reaction fuel with water in the reaction chamber to provide hydrogen and tail gases;
• transporting the tail gases from the reaction chamber through a tail gas supply line;
• transporting the combustion by-products from the combustion chamber through a combustion by-product line;
• and
• transporting the hydrogen from the reaction chamber through a reaction product line.

A method to generate hydrogen from a first reaction fuel, the method comprising:

• providing a membrane assembly to be joined to a reaction chamber of a hydrogen generator having a hydrogen plenum to form a leak tight reactor sub-assembly, the membrane assembly comprising a membrane;
• and a membrane support comprising a sintered porous metal, wherein the membrane is sealed between a first surface of the membrane support and a frame, and wherein a second surface of the membrane support is connected to the hydrogen plenum;
• reacting the first reaction fuel in the reactor chamber to provide a reaction product comprising hydrogen and tail gases;
• and
• separating the hydrogen from the tail gases in the reaction product through the membrane assembly.