US 7,922,781 B2Granted

Hydrogen generation apparatus and method for using same

OwnerAnand S. Chellappa, Michael Roy Powell +1inventors

InventorsAnand S. Chellappa, Michael Roy Powell, Charles J. Call

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Abstract

A compact hydrogen generator for use with fuel cells and other applications includes a hydrogen membrane reactor having a combustion chamber and a reaction chamber. The two chambers are have a fluid connection and a heat exchange relationship with one another. The hydrogen generation apparatus also includes a fuel supply, a fuel supply line for transporting fuel from the fuel supply to the reaction chamber, an oxygen supply, an oxygen supply line for transporting oxygen from the oxygen supply to the combustion chamber, as well as a tail gas supply line for transporting tail gas supply line for transporting tail gases from the reaction chamber, a combustion by-product line for transporting combustion by-products for the combustion chamber, and a reaction product line for transporting hydrogen from the reaction chamber.

Claims19

Dependent claims

A method for generating hydrogen in a hydrogen membrane reactor having a combustion chamber defined by a bottom plate and a separation plate and a reaction chamber defined by a top plate and the separation plate, the combustion chamber in a fluid connection with and a heat exchange relationship with the reaction chamber, the combustion chamber including a combustion catalyst, the reaction chamber including a separation membrane defining a reaction zone and an exhaust zone in the reaction chamber, the combustion chamber comprising a plurality of combustion channels defined by a first set of spaced apart fins extending from the separation plate to and in contact with the bottom plate, the reaction zone comprising a plurality of reaction channels defined by a second set of spaced apart fins extending from the separation plate to and in contact with the separation membrane, the reaction zone including a reaction catalyst, the reaction catalyst having a reaction catalyst light-off temperature, the combustion catalyst light off temperature being lower than the reaction catalyst light off temperature, the method comprising:

a. flowing stored hydrogen into the combustion chamber at a combustion catalyst light off temperature for the stored hydrogen, the combustion of the stored hydrogen generating first combustion product gases;
b. replacing the flowing stored hydrogen into the combustion chamber with a combustible fuel different from the stored hydrogen at approximately a time when the temperature of the combustion catalyst reaches a combustion catalyst light-off temperature for the combustible fuel and continuing combustion to enable the temperature of the reaction catalyst to reach the reaction catalyst light off temperature, the combustion of the combustible fuel generating second combustion byproduct gases;
c. flowing a hydrogen-producing hydrocarbon fuel other than alcohol in the reaction zone to contact the reaction catalyst at the reaction catalyst light off temperature in a range of about 550 C. to about 650 C. to produce a reaction zone hydrogen gas mixture comprising hydrogen gas and reaction tail gases, wherein flowing the hydrocarbon fuel in the reaction zone further comprises:
c1. preheating water to at least about the boiling point of the hydrocarbon fuel to produce water vapor prior to contacting the water vapor with the hydrocarbon fuel;
c2. contacting the water vapor with the hydrocarbon fuel in the reaction zone whereby said contacting reduces carbon formation in the reaction chamber;
d. separating the hydrogen gas from the reaction zone hydrogen gas mixture through the hydrogen separation membrane, said hydrogen gas accumulated into the exhaust zone of the reactor chamber;
and
e. collecting the hydrogen gas from the exhaust zone of the reaction chamber.

5 more elements

A method for generating hydrogen in a hydrogen membrane reactor comprising:

providing in the reactor a catalytic combustion chamber defined by a bottom plate and a separation plate and communicating with a catalytic reaction chamber defined by a top plate and the separation plate, the reaction chamber having therein a planar hydrogen separation membrane defining a reaction zone and an exhaust zone, the catalytic combustion chamber comprising a plurality of combustion channels defined by a first set of spaced apart fins extending from the separation plate to and in contact with the bottom plate, the reaction zone comprising a plurality of reaction channels defined by a second set of spaced apart fins extending from the separation plate to and in contact with the planar hydrogen separation membrane, the reaction zone having a reaction catalyst therein, the method comprising:
injecting stored hydrogen into the combustion chamber at a first combustion light off temperature for a combustion catalyst in the combustion chamber;
injecting a second fuel different from the stored hydrogen concurrently with termination of stored hydrogen injection into the combustion chamber when temperature in the combustion chamber reaches a second combustion light off temperature for the combustion catalyst corresponding to the second fuel;
continuing injecting the second fuel into the combustion chamber to raise the temperature of the reaction catalyst to reach a third combustion light off temperature for the reaction catalyst;
injecting a hydrogen-producing hydrocarbon fuel other than alcohol into the reaction zone at or above the third combustion light off temperature in a range of about 550 C. to about 650 C. to produce a reaction zone hydrogen gas mixture comprising hydrogen gas and reaction tail gases, wherein injecting the hydrocarbon fuel into the reaction zone further comprises:
preheating water to at least about the boiling point of the hydrocarbon fuel to produce water vapor prior to contacting the water vapor with the hydrocarbon fuel;
contacting the water vapor with the hydrocarbon fuel in the reaction zone to reduce carbon formation in the reaction chamber;
and
separating the hydrogen gas from the reaction zone gas mixture through the planar hydrogen separation membrane.

6 more elements

A method for generating hydrogen in a hydrogen membrane reactor comprising:

providing a planar catalytic combustion chamber defined between a bottom plate and a flat separation plate connected to and in thermal conduction communication with a planar catalytic reaction chamber defined between the separation plate and a top plate, the combustion chamber having therein a combustion catalyst, the planar reaction chamber having therein a planar hydrogen separation membrane defining a reaction zone and an exhaust zone, the planar catalytic combustion chamber comprising a plurality of combustion channels defined by a first set of spaced apart fins extending from the flat separation plate to and in contact with the bottom plate, the reaction zone comprising a plurality of reaction channels defined by a second set of spaced apart fins extending from the flat separation plate to and in contact with the planar hydrogen separation membrane, the reaction zone having a reaction catalyst therein, the method comprising:
injecting stored hydrogen into the combustion chamber at a combustion light off temperature for the combustion catalyst in the combustion chamber;
continuing injecting the stored hydrogen into the combustion chamber to raise the temperature of the reaction catalyst by conduction between the chambers to a combustion light off temperature for the reaction catalyst;
injecting a hydrogen-producing hydrocarbon fuel other than alcohol into the reaction zone at or above the combustion light off temperature for the reaction catalyst in a range of about 550 C. to about 650 C. to produce in the reaction zone a hydrogen gas mixture comprising hydrogen gas and reaction tail gases, wherein injecting the hydrocarbon fuel into the reaction zone further comprises:
preheating water to at least about the boiling point of the hydrocarbon fuel to produce water vapor prior to contacting the water vapor with the hydrocarbon fuel;
contacting the water vapor with the hydrocarbon fuel in the reaction zone to reduce carbon formation in the reaction chamber;
and
separating the hydrogen gas from the reaction zone gas mixture through the hydrogen separation membrane.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 11/109,220Filed 18 Apr 2005 · continuation in part
Priority: 2 Mar 2001
Published: US 2005/0172556 A122 Dec 2005
Granted: 12 Apr 2011
Term ends: Not estimatedThe source records don’t support an estimate.

Classification42 codes

B01J 19/2475
Stationary reactors without moving elements inside: membrane reactors
B01J 19/249
Reactors comprising multiple separated flow channels: plate-type reactors
C01B 3/384
Using catalysts: with external heating of the catalyst
C01B 3/501
Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification: by diffusion

Family

Application60/272,806Us provisional application · filed 2 Mar 2001
Application60/286,114Us provisional application · filed 23 Apr 2001
PCT/US02/06767Parent of this continuation-in-part · filed 4 Mar 2002
PCT/US02/12822Parent of this continuation-in-part · filed 23 Apr 2002
US 2005/0281735 A1Pre-grant publication · published 22 Dec 2005
Application10/476,015Parent of this continuation-in-part
US 7,811,529 B2Parent of this continuation-in-part
Application10/469,464Parent of this continuation-in-part
US 7,875,089 B2Parent of this continuation-in-part
US 2004/0154223 A1Published application
US 2005/0172556 A1Published application
US 7,922,781 B2This patent

From the US filing history. Foreign family members aren’t listed.