Hydrogen purification device

Abstract

To provide a hydrogen purification device and its components.SOLUTION: In some embodiments, a device may include at least one foil-microscreen assembly disposed between first and second end frames and secured to the first and second end frames. The at least one foil-microscreen assembly may include at least one hydrogen-selective membrane and at least one microscreen structure including a non-porous planar sheet disposed with a plurality of apertures forming a plurality of fluid passages. The planar sheet may include approximately opposed both surfaces configured to support to a permeate side. The plurality of fluid passages may extend between the opposed both surfaces. The at least one hydrogen-selective membrane may be metallurgically bonded to the at least one microscreen structure. In some embodiments, the device may include a permeate frame having at least one membrane support structure that spans at least a substantial portion of an open region and that is configured to support at least one foil-microscreen assembly.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. patent application Ser. No. 15 / 862,474, entitled "Hydrogen Purification Devices," filed Jan. 4, 2018, which is a continuation-in-part of U.S. patent application Ser. No. 13 / 600,096, entitled "Hydrogen Generation Assemblies," filed Aug. 30, 2012, which is a continuation-in-part of U.S. patent application Ser. No. 13 / 829,766, entitled "Hydrogen Generation Assemblies and Hydrogen Purification Devices" (U.S. Patent No. 9,187,324), filed Mar. 14, 2013, which is a continuation-in-part of U.S. patent application Ser. No. 13 / 600,096, entitled "Hydrogen Generation Assemblies," filed Aug. 30, 2012, the entire disclosures of which are incorporated herein by reference for all purposes. [Background technology]

[0002] A hydrogen generation assembly is an assembly that converts one or more feedstocks into a product stream that contains hydrogen gas as a major component. The feedstock may include a carbon-containing feedstock and, in some cases, water. The feedstock is delivered from a feedstock delivery system to a hydrogen production region of the hydrogen generation assembly, typically at an elevated temperature under pressure. The hydrogen production region is often associated with a temperature modulation assembly, such as a heating assembly or a cooling assembly, that consumes one or more fuel streams to maintain the hydrogen production region within a suitable temperature range for effectively producing hydrogen gas. The hydrogen generation assembly may generate hydrogen by any suitable mechanism, such as steam reforming, autothermal reforming, pyrolysis, and / or catalytic partial oxidation.

[0003] However, the hydrogen gas generated or produced may have impurities. The gas may include hydrogen gas and other gases and may be referred to as a mixed gas stream. Before the mixed gas stream can be used, purification is required, e.g., removing at least a portion of the other gases. Thus, the hydrogen generation assembly may include a hydrogen purification device to increase the hydrogen purity of the mixed gas stream. The hydrogen purification device may include at least one hydrogen-selective membrane that separates the mixed gas stream into a product stream and a by-product stream. The product stream may have a higher concentration of hydrogen gas and / or a lower concentration of one or more other gases than the mixed gas stream. Hydrogen purification using one or more hydrogen-selective membranes is a pressure-based separation process, and the one or more hydrogen-selective membranes are contained within a pressure vessel. The mixed gas stream contacts the surface of the membrane and a product stream is formed from at least a portion of the mixed gas stream that permeates (passes through) the membrane. The pressure vessel is typically sealed to prevent gas from entering or leaving the pressure vessel except through designated inlet and outlet ports and conduits.

[0004] The product stream may be used in a variety of applications. One such application is energy production, such as in an electrochemical fuel cell. An electrochemical fuel cell is a device that converts a fuel and an oxidant into electricity, a reaction product, and heat. For example, a fuel cell may convert hydrogen and oxygen into water and electricity. In such a fuel cell, hydrogen is the fuel, oxygen is the oxidant, and water is the reaction product. A fuel cell stack may include multiple fuel cells and be used in conjunction with a hydrogen generation assembly to provide an energy production assembly.

[0005] Examples of hydrogen generation assemblies, hydrogen processing assemblies, and / or components of such assemblies are described in U.S. Patent Nos. 5,233,633; ... and 5,233,633, the entire disclosures of which are incorporated herein by reference for all purposes. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Pat. No. 5,861,137 [Patent Document 2] U.S. Patent No. 6,319,306 [Patent Document 3] U.S. Pat. No. 6,494,937 [Patent Document 4] U.S. Patent No. 6,562,111 [Patent Document 5] U.S. Patent No. 7,063,047 [Patent Document 6] U.S. Patent No. 7,306,868 [Patent Document 7] U.S. Patent No. 7,470,293 [Patent Document 8] U.S. Patent No. 7,601,302 [Patent Document 9] U.S. Patent No. 7,632,322 [Patent Document 10] U.S. Patent No. 8,961,627 [Patent Document 11] US Patent Application Publication No. 2006 / 0090397 [Patent Document 12] US Patent Application Publication No. 2006 / 0272212 [Patent Document 13] US Patent Application Publication No. 2007 / 0266631 [Patent Document 14] US Patent Application Publication No. 2007 / 0274904 [Patent Document 15] US Patent Application Publication No. 2008 / 0085434 [Patent Document 16] US Patent Application Publication No. 2008 / 0138678 [Patent Document 17] US Patent Application Publication No. 2008 / 0230039 [Patent Document 18] US Patent Application Publication No. 2010 / 0064887 [Patent Document 19] U.S. Patent No. 5,997,594 [Patent Document 20] U.S. Patent No. 6,221,117 [Patent Document 21] U.S. Patent No. 6,537,352 [Patent Document 22] U.S. Patent No. 6,152,995 [Patent Document 23] US Patent Application Publication No. 2013 / 0011301 Summary of the Invention [Means for solving the problem]

[0007] Some embodiments may provide a hydrogen purification apparatus. In some embodiments, the hydrogen purification apparatus may include a first end frame and a second end frame including an inlet port configured to receive a mixed gas stream including hydrogen gas and other gases. The first end frame and the second end frame may further include an outlet port configured to receive a permeate stream including a higher concentration of hydrogen gas and / or a lower concentration of other gases relative to the mixed gas stream, and a by-product port configured to receive a product stream including at least a majority of the other gases. The hydrogen purification apparatus may further include at least one foil microscreen assembly disposed between and secured to the first end frame and the second end frame. The at least one foil microscreen assembly includes at least one hydrogen-selective membrane having a feed side and a permeate side. At least a portion of the permeate stream is formed from a portion of the mixed gas stream passing from the feed side to the permeate side, and a remaining portion of the mixed gas stream remaining on the feed side forms at least a portion of the by-product stream.

[0008] The at least one foil microscreen assembly further includes at least one microscreen structure including a non-porous planar sheet having a plurality of openings therethrough that form a plurality of flow passages. The planar sheet includes substantially opposed surfaces configured to support the permeate side. The plurality of flow passages extend between the surfaces. The at least one hydrogen-selective membrane is metallurgically bonded to the at least one microscreen structure. The hydrogen purification apparatus further includes a plurality of frames disposed between and secured to the first and second end frames and the at least one foil microscreen assembly. Each frame of the plurality of frames includes a peripheral shell that defines an open area.

[0009] In some embodiments, the hydrogen purification apparatus may include a first end frame and a second end frame including an inlet port configured to receive a mixed gas stream including hydrogen gas and other gases. The first end frame and the second end frame may further include an outlet port configured to receive a permeate stream including a high concentration of hydrogen gas and / or a low concentration of other gases relative to the mixed gas stream, and a by-product port configured to receive a by-product stream including at least a majority of the other gases. The hydrogen purification apparatus further includes at least one foil microscreen assembly disposed between and secured to the first end frame and the second end frame. The at least one foil microscreen assembly includes at least one hydrogen-selective membrane having a feed side and a permeate side. At least a portion of the permeate stream is formed from a portion of the mixed gas stream passing from the feed side to the permeate side, and a remaining portion of the mixed gas stream remaining on the feed side forms at least a portion of the by-product stream. The at least one foil microscreen assembly further includes at least one microscreen structure including generally opposed faces configured to support the permeate side and a plurality of flow channels extending between the generally opposed faces. The at least one hydrogen-selective membrane is metallurgically bonded to the at least one microscreen structure.

[0010] The hydrogen purification apparatus further includes a plurality of frames disposed between and secured to the first and second end frames and the at least one foil microscreen assembly. The plurality of frames includes at least one permeate frame disposed between the at least one foil microscreen assembly and the second end frame. The at least one permeate frame includes a peripheral shell and an outlet conduit formed in the peripheral shell and configured to receive at least a portion of a permeate stream from the at least one hydrogen-selective membrane. The at least one permeate frame further includes an open area surrounded by the peripheral shell and at least one membrane support structure spanning at least a majority of the open area and configured to support the at least one foil microscreen assembly. The at least one membrane support structure is non-perforated (has no through holes).

[0011] Some embodiments may provide a foil microscreen assembly. The foil microscreen assembly may include at least one hydrogen-selective membrane having a feed side and a permeate side. The at least one hydrogen-selective membrane may be configured to receive a mixed gas stream and form a permeate stream from a portion of the mixed gas stream passing from the feed side to the permeate side and form a by-product stream from a remaining portion of the mixed gas stream remaining on the feed side. The foil microscreen assembly may further include at least one microscreen structure including a non-porous planar sheet having a plurality of openings therein forming a plurality of flow passages. The planar sheet may include substantially opposed surfaces configured to support the permeate side. The plurality of flow passages may extend between the opposed surfaces. The permeate side of the at least one hydrogen-selective membrane may be metallurgically bonded to the at least one microscreen structure. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic diagram of an example of a hydrogen generation assembly. [Diagram 2] FIG. 2 is a schematic diagram of another example of a hydrogen generation assembly. [Diagram 3] FIG. 2 is a schematic diagram of a hydrogen purification apparatus of the hydrogen generation assembly of FIG. 1. [Figure 4] FIG. 4 is an isometric exploded view of the example hydrogen purification apparatus of FIG. [Diagram 5] FIG. 5 is a top view of an example foil microscreen assembly of the hydrogen purification apparatus of FIG. 4. [Figure 6] 6 is a top view of an example microscreen structure of the foil microscreen assembly of FIG. 5. [Figure 7] 7 is a partial view of the microscreen structure of FIG. 6 having another example aperture. [Figure 8] 7 is a partial view of the microscreen structure of FIG. 6 having yet another example aperture. [Figure 9] 7 is a partial view of the microscreen structure of FIG. 6 with further example apertures. [Figure 10] FIG. 5 is a top view of another example of a foil microscreen assembly of the hydrogen purification apparatus of FIG. 4. [Figure 11] 11 is a top view of an example microscreen structure of the foil microscreen assembly of FIG. 10. [Figure 12] FIG. 5 is a top view of another example of a foil microscreen assembly of the hydrogen purification apparatus of FIG. 4. [Figure 13] 5 is a top view of a further example of a foil microscreen assembly of the hydrogen purification apparatus of FIG. 4. [Figure 14] FIG. 5 is a partial cross-sectional view of an example permeate frame, foil microscreen assembly, gasket frame, and feed frame of the hydrogen purification apparatus of FIG. 4, shown without the gasket frame between the foil microscreen assembly and the permeate frame. [Figure 15] FIG. 5 is a top view of the hydrogen purification apparatus of FIG. 4, showing an example of a surrounding shell of the permeation frame and a membrane support structure of the permeation frame. [Figure 16] 5 is a partial cross-sectional view of another example of a peripheral shell of the permeation frame of the hydrogen purification apparatus of FIG. 4. [Figure 17] 5 is an isometric view of an example of a membrane support plate of a membrane support structure of a permeation frame of the hydrogen purification apparatus of FIG. 4. [Figure 18]5 is an isometric view of another example of a membrane support plate of the membrane support structure of the permeation frame of the hydrogen purification apparatus of FIG. 4. [Figure 19] 5 is a cross-sectional view of another example of the membrane support structure of the hydrogen purification apparatus of FIG. 4. [Figure 20] FIG. 4 is an isometric exploded view of another example of the hydrogen purification apparatus of FIG. 3. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] 1 illustrates an example of a hydrogen generation assembly 20. Unless otherwise specified, the hydrogen generation assembly 20 may include one or more components of the other hydrogen generation assemblies described herein. The hydrogen generation assembly may include any suitable structure configured to generate a product hydrogen stream 21. For example, the hydrogen generation assembly may include a feedstock delivery system 22 and a fuel processing assembly 24. The feedstock delivery system may include any suitable structure configured to selectively deliver at least one feed stream 26 to the fuel processing assembly.

[0014] In some embodiments, the feedstock delivery system 22 may further include any suitable structure configured to selectively deliver at least one fuel stream 28 to a burner or other heating assembly of the fuel processing assembly 24. In some embodiments, the feedstock stream 26 and the fuel stream 28 may be the same stream delivered to different portions of the fuel processing assembly. The feedstock delivery system may include any suitable transport mechanism, such as a positive displacement or other suitable pump or mechanism for propelling a fluid stream. In some embodiments, the feedstock delivery system may be configured to deliver the feedstock stream 26 and / or the fuel stream 28 without the need for a pump and / or other electrically powered fluid transport mechanism. Examples of suitable feedstock delivery systems that may be used with the hydrogen generation assembly 20 include the feedstock delivery systems described in U.S. Patent Nos. 5,399,623, 5,433, 5,511, 5,625, 5,791, 6,771, 6,825, 7,971, 7 ...

[0015] Feed stream 26 may include at least one hydrogen production fluid 30, which may include one or more fluids that may be used as reactants to produce product hydrogen stream 21. For example, hydrogen production stream may include at least one carbon-containing feedstock, such as hydrocarbons and / or alcohols. Examples of suitable hydrocarbons include methane, propane, natural gas, diesel, kerosene, gasoline, and the like. Examples of suitable alcohols include methanol, ethanol, polyols (such as ethylene glycol and propylene glycol), and the like. Additionally, hydrogen production fluid 30 may include water, such as when fuel processing assembly 24 produces the product hydrogen stream via steam reforming and / or autothermal reforming. When fuel processing assembly 24 produces the product hydrogen stream via pyrolysis or catalytic partial oxidation, feed stream 26 does not include water.

[0016] In some embodiments, the feedstock delivery system 22 may be configured to deliver a hydrogen production fluid 30 that includes a mixture of water and a water-compatible carbon-containing feedstock (methanol and / or other water-compatible alcohols). The ratio of water to carbon-containing feedstock in such a fluid stream may vary according to one or more factors, such as the particular carbon-containing feedstock used, the user's preferences, the design of the fuel processing assembly, the mechanism used in the fuel processing assembly to generate the product hydrogen stream, etc. For example, the water to carbon molar ratio may be about 1:1 to 3:1. Additionally, a mixture of water and methanol may be delivered at or near a 1:1 molar ratio (37% water and 63% methanol by weight), while a mixture of hydrocarbons or other alcohols may be delivered with a water to carbon molar ratio greater than 1:1.

[0017] When the fuel processing assembly 24 produces the product hydrogen stream 21 via reforming, the feed stream 26 may contain, for example, about 25-75% by volume methanol or ethanol (or other suitable water-compatible carbon-containing feedstock) and about 25-75% by volume water. For feed streams that contain at least substantially methanol and water, these streams may contain about 50-75% by volume methanol and about 25-50% by volume water. Streams containing ethanol or other water-compatible alcohols may contain about 25-60% by volume alcohol and about 40-75% by volume water. An example feed stream for a hydrogen generation assembly 20 using steam reforming or autothermal reforming contains 69% by volume methanol and 31% by volume water.

[0018] Although the feedstock delivery system 22 is shown as being configured to deliver a single feed stream 26, the feedstock delivery system may be configured to deliver two or more feed streams 26. These streams may contain the same or different feedstocks, may have different compositions, may have at least one common component, may have no common components, or may have the same composition. For example, a first feed stream may include a first component, such as a carbon-containing feedstock, and a second feed stream may include a second component, such as water. Additionally, while the feedstock delivery system 22 may be configured in some embodiments to deliver a single fuel stream 28, the feedstock delivery system may be configured to deliver two or more fuel streams. The fuel streams may have different compositions, may have at least one common component, may have no common components, or may have the same composition. Additionally, the feed stream and the fuel stream may exit the feed delivery system in various phases. For example, one of the streams may be a liquid stream while the other stream is a gas stream. In some embodiments, both of the streams may be liquid streams, while in other embodiments, both of the streams may be gas streams. Additionally, although the hydrogen generation assembly 20 is shown as including a single feedstock delivery system 22, the hydrogen generation assembly may include two or more feedstock delivery systems 22.

[0019] The fuel processing assembly 24 may include a hydrogen-producing region 32 configured to produce an output stream 34 including hydrogen gas via any suitable hydrogen production mechanism. The output stream may include hydrogen gas as at least a major component and may also include additional gaseous components. Thus, the output stream 34 may be referred to as a "mixed gas stream" that includes hydrogen gas as a major component, but also includes other gases.

[0020] The hydrogen-producing region 32 may include any suitable catalyst-containing bed or region. When the hydrogen production mechanism is steam reforming, the hydrogen-producing region may include a suitable steam reforming catalyst 36 to facilitate production of an output stream 34 from a feed stream 26 that includes a carbon-containing feedstock and water. In such an embodiment, the fuel processing assembly 24 may be referred to as a "steam reformer," the hydrogen-producing region 32 may be referred to as a "reforming region," and the output stream 34 may be referred to as a "reformed stream." Other gases that may be present in the reformed stream include carbon monoxide, carbon dioxide, methane, water steam, and / or unreacted carbon-containing feedstock.

[0021] Where the hydrogen production mechanism is autothermal reforming, the hydrogen-production region 32 may include a suitable autothermal reforming catalyst to facilitate production of the effluent stream 34 from the feed stream 26 comprising water and the carbon-containing feedstock in the presence of air. Additionally, the fuel processing assembly 24 may include an air delivery assembly 38 configured to deliver an air stream to the hydrogen-production region.

[0022] In some embodiments, the fuel processing assembly 24 may include a purification (or separation) region 40, which may include any suitable structure configured to produce at least one hydrogen-rich stream 42 from the effluent (or mixed gas) stream 34. The hydrogen-rich stream 42 may include a higher hydrogen concentration compared to the effluent stream 34 and / or may include a lower concentration of one or more other gases (or impurities) that were present in the effluent stream. The product hydrogen stream 21 includes at least a portion of the hydrogen-rich stream 42. As a result, the product hydrogen stream 21 and the hydrogen-rich stream 42 may be the same stream and may have the same composition and flow rate. Alternatively, some of the purified hydrogen gas in the hydrogen-rich stream 42 may be stored, such as in a suitable hydrogen storage assembly, for later use and / or may be used by the fuel processing assembly. The purification region 40 may be referred to as a "hydrogen purifier" or a "hydrogen processing assembly."

[0023] In some embodiments, the refining region 40 may produce at least one by-product stream 44, which may contain no hydrogen gas or may contain some hydrogen gas. The by-product stream may be vented, sent to a burner assembly and / or other combustion source, used as a heated fluid stream, stored for later use, and / or otherwise used, stored, and / or disposed of. Additionally, the refining region 40 may discharge the by-product stream as a continuous stream depending on the transport of the effluent stream 34, or may discharge the by-product stream intermittently, for example, in a batch process or where a by-product portion of the effluent stream is at least temporarily retained in the refining region.

[0024] The fuel processing assembly 24 may include one or more purification regions configured to produce one or more by-product streams that include a sufficient amount of hydrogen gas suitable for use as a fuel stream (or feed stream) for a heating assembly for the fuel processing assembly. In some embodiments, the by-product streams may have a hydrogen content that provides sufficient fuel value or a heating assembly to maintain the hydrogen production region at a predetermined operating temperature or within a selected temperature range. For example, the by-product streams may include hydrogen gas at 10-30% by volume hydrogen gas, 15-25% by volume hydrogen gas, 20-30% by volume hydrogen gas, at least 10 or 15% by volume hydrogen gas, at least 20% by volume hydrogen gas, etc.

[0025] The purification region 40 may include any suitable structure configured to increase (and / or enhance) the concentration of at least one component of the output stream 21. In many applications, the hydrogen-rich stream 42 will have a high hydrogen concentration compared to the output stream (or mixed gas stream) 34. The hydrogen-rich stream may have a low concentration of one or more non-hydrogen components that were present in the output stream 34, with the hydrogen concentration of the hydrogen-rich stream being greater than, the same as, or less than the output stream. For example, in a conventional fuel cell system, carbon monoxide, even if present at a few ppm, may damage the fuel cell stack, while other non-hydrogen components, such as water, that may be present in the output stream 34, may not damage the stack even if present at higher concentrations. Thus, in such applications, the purification region may not increase the overall concentration of hydrogen, but may reduce the concentration of one or more non-hydrogen components that are or may be harmful to a given application of the product hydrogen stream.

[0026] Examples of suitable equipment for the purification region 40 include one or more hydrogen-selective membranes 46, a chemical carbon monoxide removal assembly 48, and / or a pressure swing adsorption (PSA) system 50. The purification region 40 may include one or more types of purification equipment, which may have the same or different structures and / or may operate with the same or different mechanisms. The fuel processing assembly 24 may include at least one restrictive orifice and / or other flow restrictor downstream of the purification region, such as in association with one or more product hydrogen streams, a hydrogen-rich stream, and / or a by-product stream.

[0027] The hydrogen-selective membrane 46 is permeable to hydrogen gas but is at least substantially (if not completely) impermeable to other components of the effluent stream 34. The membrane 46 may be formed of any hydrogen-permeable material suitable for use in the operating environment and parameters under which the purification region 40 is operated. Examples of suitable materials for the membrane 46 include palladium and palladium alloys, particularly thin films of such metals and metal alloys. Palladium alloys have proven particularly effective, particularly palladium having 35% to 45% copper by weight. A palladium-copper alloy containing approximately 40% copper by weight has proven particularly effective, although other relative concentrations and components may be used. Three other particularly useful alloys are palladium with 2 to 20% gold by weight (particularly palladium with 5% gold by weight), palladium with 3 to 10% indium and 0 to 10% ruthenium by weight (particularly palladium with 6% indium and 0.5% ruthenium by weight), and palladium with 20 to 30% silver by weight. When palladium and palladium alloys are used, the hydrogen-selective membrane 46 may sometimes be referred to as a "foil." The typical thickness of the hydrogen-permeable metal foil is less than 25 micrometers (μm), preferably 15 micrometers or less, and most preferably between 5 and 12 micrometers. The foil may be of any suitable size, for example 110 mm by 270 mm.

[0028] The chemical carbon monoxide removal assembly 48 is a device that chemically reacts with carbon monoxide and / or other undesirable components of the effluent stream 34 to form other compositions that are not potentially harmful. Examples of chemical carbon monoxide removal assemblies include water-gas shift reactors configured to produce hydrogen gas and carbon dioxide from water and carbon monoxide, partial oxidation reactors that convert carbon monoxide and oxygen (usually from air) into carbon dioxide, and methanation reactors configured to convert carbon monoxide and hydrogen into methane and water. The fuel processing assembly 24 may include one or more and / or more than one chemical removal assemblies 48.

[0029] Pressure swing adsorption (PSA) is a chemical process in which gaseous impurities are removed from the effluent stream 34 based on the principle that certain gases are more strongly adsorbed onto an adsorbent material than other gases under suitable temperature and pressure conditions. Typically, non-hydrogen impurities are adsorbed and removed from the effluent stream 34. Adsorption of impurity gases occurs at high pressures. When the pressure is reduced, the impurities are desorbed from the adsorbent material, resulting in regeneration of the adsorbent. Typically, PSA is a cyclic process, requiring at least two beds for continuous (as opposed to batch) operation. Examples of suitable adsorbent materials that may be used in the adsorption beds are activated carbon and zeolites. The PSA system 50 also provides an example of an apparatus for use in the purification region 40 in which by-products or removed components are not directly vented from the region because the gas stream is simultaneous with the purification of the effluent stream. Instead, these by-product components are removed when the adsorbent material is regenerated or otherwise removed from the purification region.

[0030] In Figure 1, purification region 40 is shown inside fuel processing assembly 24. The purification region may alternatively be located separately downstream from the fuel processing assembly, as shown diagrammatically by dashed lines in Figure 1. Purification region 40 may include portions inside and outside the fuel processing assembly.

[0031] The fuel processing assembly 24 may include a temperature modulation assembly in the form of a heating assembly 52. ​​The heating assembly may be configured to generate at least one heated exhaust stream (or combustion stream) 54 from at least one heated fuel stream 28, typically when combusted in the presence of air. The heated exhaust stream 54 is shown diagrammatically in FIG. 1 as heating the hydrogen-producing region 32. The heating assembly 52 may include any suitable structure configured to generate a heated exhaust stream, such as a burner or combustion catalyst in which a fuel is combusted with air to create a heated exhaust stream. The heating assembly may include an ignition device or ignition source 58 configured to initiate combustion of the fuel. Examples of suitable ignition sources include one or more spark plugs, glow plugs, combustion catalysts, pilot lights, piezoelectric ignition devices, spark ignition devices, hot surface ignition devices, and the like.

[0032] In some embodiments, the heating assembly 52 may include a burner assembly 60 and may be referred to as a combustion-based or combustion-driven heating assembly. In a combustion-based heating assembly, the heating assembly 52 may be configured to receive at least one fuel stream 28 and combust the fuel stream in the presence of air to provide a thermal combustion stream 54 that may be used to heat at least the hydrogen-production region of the fuel processing assembly. Air may be delivered to the heating assembly via a variety of mechanisms. For example, an air stream 62 may be delivered to the heating assembly as a separate stream, as shown in FIG. 1. Alternatively or additionally, the air stream 62 may be delivered to the heating assembly along with the at least one fuel stream 28 for the heating assembly 52 and / or may be drawn from the environment in which the heating assembly is used.

[0033] The combustion stream 54 may additionally or alternatively be used to heat the fuel processing assembly and / or other portions of the fuel cell system in which the heating assembly is used. Additionally, other configurations and types of heating assemblies 52 may be used. For example, the heating assembly 52 may be an electrically powered heating assembly configured to heat at least the hydrogen-production region 32 of the fuel processing assembly 24 by generating heat using at least one heating element, such as a resistive heating element. In these embodiments, the heating assembly 52 need not receive and combust a combustible fuel stream to heat the hydrogen-production region to a suitable hydrogen production temperature. An example of a heating assembly is disclosed in U.S. Patent No. 6,399,933, the entire disclosure of which is incorporated herein by reference for all purposes.

[0034] The heating assembly 52 may be housed in a common shell or housing with the hydrogen-production region and / or the separation region (discussed further below). The heating assembly may be positioned separately from the hydrogen-production region 32, but in thermal and / or fluid communication with at least the region that provides predetermined heating of the hydrogen-production region. The heating assembly 52 may be partially or completely disposed within a common shell, and / or at least a portion (or all) of the heating assembly may be disposed outside of the shell. If the heating assembly is disposed outside of the shell, hot combustion gases from the burner assembly 60 may be conveyed to one or more components within the shell via suitable heat transfer conduits.

[0035] The heating assembly may be configured to heat the feed delivery system 22, the feed stream, the hydrogen production region 32, the purification (or separation) region 40, or any suitable combination of these systems, streams, and regions. Heating the feed stream may include vaporizing components of the liquid reaction stream or the hydrogen production fluid used to produce hydrogen gas in the hydrogen production region. In this embodiment, the fuel processing assembly 24 may be described as including an evaporation region 64. The heating assembly may be further configured to heat other components of the hydrogen generation assembly. For example, the heated exhaust stream may be configured to heat a pressure vessel and / or other canister containing the heated fuel and / or hydrogen production fluid that forms at least a portion of the feed stream 26 and the fuel stream 28.

[0036] The heating assembly 52 may provide and / or maintain any suitable temperature within the hydrogen-producing region 32. Steam reformers typically operate at temperatures ranging from 200° C. to 900° C. However, temperatures outside this range are within the scope of the present disclosure. When the carbon-containing feedstock is methanol, the steam reforming reaction typically occurs in the range of approximately 200-500° C. Examples of subsets of this range include 350-450° C., 375-425° C., and 375-400° C. When the carbon-containing feedstock is a hydrocarbon, ethanol, or other alcohol, a temperature range of approximately 400-900° C. is typically used for the steam reforming reaction. Examples of subsets of this range include 750-850°C, 725-825°C, 650-750°C, 700-800°C, 700-900°C, 500-800°C, 400-600°C, and 600-800°C. The hydrogen-production region 32 may include two or more sections, or portions, each of which may operate at the same or different temperatures. For example, if the hydrogen production fluid includes a hydrocarbon, the hydrogen-production region 32 may include two different hydrogen-producing sections, or regions, one operating at a lower temperature than the other, providing a pre-reforming region. In these embodiments, the fuel processing assembly may also be described as including two or more hydrogen-production regions.

[0037] Fuel stream 28 may include any combustible liquid and / or gas suitable for consumption by heating assembly 52 to provide a given heat production. Some fuel streams may be gaseous when transported and combusted by heating assembly 52, while other fuel streams may be delivered to the heating assembly as liquid streams. Examples of suitable heating fuels for fuel stream 28 include carbon-containing feedstocks such as methanol, methane, ethane, ethanol, ethylene, propane, propylene, butane, and the like. Further examples include low molecular weight compressible fuels such as liquefied petroleum gas, ammonia, light amines, dimethyl ether, and low molecular weight hydrocarbons. Still other examples include hydrogen and carbon monoxide. In embodiments of hydrogen generation assembly 20 that include a temperature modulation assembly in the form of a cooling assembly instead of a heating assembly (which may be used when an exothermic hydrogen generation process (e.g., partial oxidation) is used instead of an endothermic process such as steam reforming), a feedstock delivery system may be configured to supply a fuel or coolant stream to the assembly. Any suitable fuel or coolant fluid may be used.

[0038] The fuel processing assembly 24 may further include a shell or housing 66 in which at least the hydrogen production region 32 is included, as shown in FIG. 1. In some embodiments, the evaporation region 64 and / or purification region 40 may further be included within the shell. The shell 66 may allow the components of the steam reformer or other fuel processing mechanism to be moved as a unit. The shell may protect the components of the fuel processing assembly from damage by providing a protective enclosure and / or may reduce the need to heat the fuel processing assembly since the components may be heated as a unit. The shell 66 may include an insulating material 68, such as a solid insulating material, a blanket insulating material, and / or an air-filled cavity. The insulating material may be inside the shell, outside the shell, or both. If the insulating material is outside the shell, the fuel processing assembly 24 may further include an outer cover or jacket 70, outside the insulation, as shown generally in FIG. 1. The fuel processing assembly may include different shells that contain additional components of the fuel processing assembly, such as the feedstock delivery system 22 and / or other components.

[0039] One or more components of the fuel processing assembly 24 may extend beyond the shell or may be located outside the shell. For example, the purification region 40 may be located outside the shell 66, such as being separate from the shell but in fluid communication with it by suitable fluid transfer conduits. As another example, a portion of the hydrogen-production region 32 (such as a portion of one or more reforming catalyst beds) may extend beyond the shell, such as that shown diagrammatically in dotted lines representing alternative shell configurations in FIG. 1. Examples of suitable hydrogen generation assemblies and components thereof are disclosed in U.S. Patent Nos. 5,399, 6,433, 6,513, 6,711, 6,893, 7,943, 7,971, 7,982, 7,996, 8,103, 9,112, 9,122, 9,136, 9,141, 9,152, 9,162, 9,176, 9,181, 9,193, 9,162, 9,176, 9,182, 9,193, 9,194, 9,136, 9,142, 9,152, 9,162, 9,176, 9,182, 9,193, 9,194, 9,195, 9,196, 9,197, 9,198, 9,199, 9,103, 9,104, 9,105, 9,106, 9,107, 9,109, 9,110, 9,112, 9,114, 9,122, 9,136, 9,142, 9,152, 9,162, 9,17

[0040] Another example of a hydrogen generation assembly 20 is shown generally at 72 in FIG. 2. Unless otherwise noted, hydrogen generation assembly 72 may include one or more components of hydrogen generation assembly 20. Hydrogen generation assembly 72 may include a feedstock delivery system 74, an evaporation region 76, a hydrogen production region 78, and a heating assembly 80, as shown in FIG. 2. In some embodiments, hydrogen generation assembly 20 may include a purification region 82.

[0041] The feedstock delivery system may include any suitable structure configured to deliver one or more feed streams and / or fuel streams to one or more other components of the hydrogen generation assembly. For example, the feedstock delivery system may include a feedstock tank (or container) 84 and a pump 86. The feedstock tank may contain any suitable hydrogen production fluid 88, such as water and a carbon-containing feedstock (e.g., a methanol / water mixture). The pump 86 may have any suitable structure configured to deliver the hydrogen production fluid to the evaporation region 76 and / or the hydrogen production region 78, and the hydrogen production fluid may be in the form of at least one liquid-containing feed stream 90 that includes water and a carbon-containing feedstock.

[0042] Evaporation region 76 may include any suitable structure configured to receive and vaporize at least a portion of a liquid-containing feed stream, such as liquid-containing feed stream 90. For example, evaporation region 76 may include an evaporator 92 configured to at least partially convert liquid-containing feed stream 90 into one or more vapor feed streams 94. The vapor feed stream may include a liquid, in some embodiments. An example of a suitable evaporator includes a coiled tube evaporator, such as a coiled stainless steel tube.

[0043] The hydrogen-production region 78 may include any suitable structure configured to receive one or more feed streams, such as the steam feed stream 94, from the evaporation region and produce one or more output streams 96 that include hydrogen gas as a primary component and other gases. The hydrogen-production region may produce the output streams via any suitable mechanism. For example, the hydrogen-production region 78 may generate the output stream 96 via a steam reforming reaction. In this example, the hydrogen-production region 78 may include a steam reforming region 97 with a reforming catalyst 98 configured to facilitate and / or promote the steam reforming reaction. When the hydrogen-production region 78 generates the output stream 96 via a steam reforming reaction, the hydrogen generation assembly 72 may be referred to as a “steam reforming hydrogen generation assembly” and the output stream 96 may be referred to as a “reformed stream.”

[0044] Heating assembly 80 may include any suitable structure configured to generate at least one heated exhaust stream 99 for heating one or more components of hydrogen generation assembly 72. For example, the heating assembly may heat the evaporation region to any suitable temperature, such as at least a minimum evaporation temperature or a temperature at which at least a portion of the liquid-containing feed stream is evaporated to form a vapor feed stream. Additionally or alternatively, heating assembly 80 may heat the hydrogen-production region to any suitable temperature, such as at least a minimum hydrogen production temperature or a temperature at which at least a portion of the vapor feed stream is reacted to produce hydrogen gas and form an outlet stream. The heating assembly may be in thermal communication with one or more components of the hydrogen generation assembly, such as the evaporation region and / or the hydrogen-production region.

[0045] The heating assembly may include a burner assembly 100, at least one blower 102, and an ignition assembly 104, as shown in FIG. 2. The burner assembly may include any suitable structure configured to receive at least one air stream 106 and at least one fuel stream 108, and to combust the at least one fuel stream within a combustion region 110 to produce a heated exhaust stream 99. The fuel streams may be provided by the feedstock delivery system 74 and / or the purification region 82. The combustion region may be included within an enclosure of the hydrogen generation assembly. The blower 102 may include any suitable structure configured to generate the air stream 106. The ignition assembly 104 may include any suitable structure configured to ignite the fuel stream 108.

[0046] The purification region 82 may include any suitable structure configured to produce at least one hydrogen-rich stream 112, which may have a high hydrogen concentration compared to the output stream 96 and / or may include a low concentration of one or more other gases (or impurities) that were present in the output stream. The purification region may produce at least one by-product or fuel stream 108, which may be sent to the burner assembly 100 and used as a fuel stream for that assembly, as shown in FIG. 2. The purification region 82 may include a flow restriction orifice 111, a filter assembly 114, a membrane assembly 116, and a methanation reactor assembly 118. A filter assembly (such as one or more hot gas filters) may be configured to remove impurities from the output stream 96 prior to the hydrogen purification membrane assembly.

[0047] The membrane assembly 116 may include any structure configured to receive the effluent gas stream or mixed gas stream 96 containing hydrogen gas and other gases, and to produce or permeate the hydrogen-rich stream 112 containing a higher concentration of hydrogen gas and / or a lower concentration of other gases compared to the mixed gas stream. The membrane assembly 116 may incorporate planar or tubular hydrogen-permeable (or hydrogen-selective) membranes, and one or more hydrogen-permeable membranes may be incorporated into the membrane assembly 116. The permeate stream may be used in connection with any suitable application, such as one or more fuel cells. In some embodiments, the membrane assembly may produce a by-product or fuel stream 108 that includes at least a majority of other gases. The methanation reactor assembly 118 may include any suitable structure configured to convert carbon monoxide and hydrogen to methane and water. Although purification region 82 is shown to include flow restriction orifice 111, filter assembly 114, membrane assembly 116, and methanation reactor assembly 118, the purification region may not have all of these assemblies and / or may alternatively or additionally include one or more other components configured to purify effluent stream 96. For example, purification region 82 may include only membrane assembly 116.

[0048] In some embodiments, hydrogen generation assembly 72 may include a shell or housing 120 that may at least partially contain one or more of the other components of the assembly. For example, shell 120 may at least partially contain evaporation region 76, hydrogen production region 78, heating assembly 80, and / or purification region 82, as shown in FIG. 2. Shell 120 may include one or more exhaust ports 122 configured to exhaust at least one combustion exhaust stream 124 produced by heating assembly 80.

[0049] The hydrogen generation assembly 72 may, in some embodiments, include a control system 126, which may include any suitable structure configured to control the operation of the hydrogen generation assembly 72. For example, the control system 126 may include a control assembly 128, at least one valve 130, at least one pressure relief valve 132, and one or more temperature measurement devices 134. The control assembly 128 may sense the temperature within the hydrogen production area and / or purification area via the temperature measurement device 134, which may include one or more thermocouples and / or other suitable devices. Based on the sensed temperature, an operator of the control assembly and / or control system may adjust the delivery of the feed stream 90 to the evaporation area 76 and / or hydrogen production area 78 via the valve 130 and pump 86. The valve 130 may include a solenoid valve and / or any suitable valve. The pressure relief valve 132 may be configured to ensure that excess pressure in the system is relieved.

[0050] In some embodiments, hydrogen generation assembly 72 may include a heat exchange assembly 136, which may include one or more heat exchangers 138 configured to transfer heat from one portion of the hydrogen generation assembly to another portion. For example, heat exchange assembly 136 may transfer heat from hydrogen-rich stream 112 to feed stream 90 to increase the temperature of the feed stream prior to entering evaporation region 76, as well as to cool hydrogen-rich stream 112.

[0051] An example of the purification region 40 (or hydrogen purification apparatus) of the hydrogen generation assembly 20 of FIG. 1 is shown generally at 144 in FIG. 3. Unless otherwise noted, the hydrogen purification apparatus may include one or more components of the other purification regions disclosed herein. The hydrogen purification apparatus 40 may include a hydrogen separation region 146 and a housing 148. The housing may define an interior space 150 having an interior perimeter 152. The housing 148 may include at least a first portion 154 and a second portion 156 that are coupled together to form a body 149 in the form of a sealed pressure vessel that may include defined inlet and outlet ports. These ports may define flow paths through which gases and other fluids may be conveyed to and removed from the interior space of the housing.

[0052] The first portion 154 and the second portion 156 may be coupled together using any suitable retention mechanism or structure 158. Examples of suitable retention structures include welds and / or bolts. Examples of seals used to provide a fluid-tight interface between the first and second portions include gaskets and / or welds. Additionally or alternatively, the first portion 154 and the second portion 156 may be secured together to provide at least a predetermined amount of compression to the various components defining the hydrogen separation region within the housing and / or other components that may be incorporated into the hydrogen generation assembly. The compression provided may ensure that the various components are held in place within the housing. Additionally or alternatively, the compression provided to the various components defining the hydrogen separation region and / or other components may provide a fluid-tight interface between the various components defining the hydrogen separation region, between the various other components, and / or between the various components defining the hydrogen separation region and other components.

[0053] The housing 148 may include a mixed gas region 160 and a permeate region 162, as shown in FIG. 3. The mixed gas region and the permeate region may be separated by a hydrogen separation region 146. At least one inlet port 164 may be provided through which a fluid stream 166 is delivered to the housing. The fluid stream 166 may be a mixed gas stream 168 including hydrogen gas 170 and other gases 172 delivered to the mixed gas region 160. Hydrogen gas may be a major component of the mixed gas stream. The hydrogen separation region 146 extends between the mixed gas region 160 and the permeate region 162 such that gas in the mixed gas region must pass through the hydrogen separation region to enter the permeate region. The gas may be required to pass through at least one hydrogen selective membrane, for example, as discussed further below. The permeate region and the mixed gas region may have any suitable relative sizes within the housing.

[0054] The housing 148 may include at least one product outlet port 174 through which a permeate stream 176 may be received and removed from the permeate region 162. The permeate stream may include a high concentration of hydrogen gas and / or a low concentration of other gases relative to the mixed gas stream. The permeate stream 176 may, in some embodiments, at least initially include a carrier gas component or a sweep gas component, such as may be transported as a sweep gas stream 178 through a sweep gas port 180 in fluid communication with the permeate region. The housing may include at least one by-product outlet port 182 through which a by-product stream 184 including a majority of the other gases 172 and / or a low concentration (relative to the mixed gas stream) of hydrogen gas 170 may be removed from the mixed gas region.

[0055] Hydrogen separation region 146 may include at least one hydrogen-selective membrane 186 having a first surface or mixed gas surface 188 (oriented to contact mixed gas stream 168) and a second surface or permeate surface 190 (generally opposite surface 188). Mixed gas stream 168 may be conveyed to the mixed gas region of the enclosure so as to contact the mixed gas surfaces of one or more hydrogen-selective membranes. Permeate stream 176 may be formed from at least a portion of the mixed gas stream that passes through the hydrogen separation region to permeate region 162. By-product stream 184 may be formed from at least a portion of the mixed gas stream that does not pass through the hydrogen separation region. In some embodiments, by-product stream 184 may include a portion of the hydrogen gas present in the mixed gas stream. The hydrogen separation region may be configured to trap or otherwise retain at least a portion of other gases, which may then be removed as a by-product stream when the separation region is replaced, regenerated, or otherwise recharged.

[0056] 3 , streams 166, 176, 178, and / or 184 may include one or more actual streams flowing into or out of hydrogen purification device 144. For example, hydrogen purification device may receive multiple mixed gas streams 168, a single mixed gas stream 168 that is split into two or more streams before contacting hydrogen separation region 146, a single stream that is conveyed within interior space 150, etc. As such, housing 148 may include one or more inlet ports 164, product outlet ports 174, sweep gas ports 180, and / or by-product outlet ports 182.

[0057] The hydrogen-selective membrane may be formed of any hydrogen-permeable material suitable for use in the operating environment and parameters in which the hydrogen purification apparatus operates. Examples of hydrogen purification apparatus are disclosed in U.S. Patent Nos. 5,399,623 and 5,433,792, the entire disclosures of which are incorporated herein by reference for all purposes. In some embodiments, the hydrogen-selective membrane may be formed from at least one of palladium and palladium alloys. Examples of palladium alloys include palladium and copper, palladium and silver, and / or palladium and gold. Examples of various membranes, membrane configurations, and methods of preparing membranes and membrane configurations are disclosed in U.S. Patent Nos. 5,399,623, 5,433,623, 5,433,792, and 5,433,792, the entire disclosures of which are incorporated herein by reference for all purposes.

[0058] In some embodiments, a plurality of spaced apart hydrogen-selective membranes 186 may be used within the hydrogen-separation region to form at least a portion of a hydrogen-separation assembly 192. When present, the plurality of membranes may collectively define one or more membrane assemblies. In such embodiments, the hydrogen-separation assembly may extend generally from the first portion 154 to the second portion 156. As a result, the first and second portions may effectively compress the hydrogen-separation assembly. In some embodiments, the housing 148 may additionally or alternatively include end plates (or end frames) coupled to opposite sides of the body portion. In such embodiments, the end plates may effectively compress the hydrogen-separation assembly (and other components that may be housed within the housing) between a pair of opposing end plates.

[0059] Hydrogen purification using one or more hydrogen-selective membranes is typically a pressure-driven separation process in which a mixed gas stream is conveyed in contact with the mixed gas surface of the membrane at a pressure elevated relative to the gas in the permeate region of the hydrogen separation region. The hydrogen separation region, in some embodiments, when used to separate a mixed gas stream into a permeate stream and a by-product stream, may be heated to an elevated temperature via any suitable mechanism. Examples of suitable operating temperatures for hydrogen purification using palladium and palladium alloy membranes include temperatures of at least 275° C., temperatures of at least 325° C., temperatures of at least 350° C., temperatures in the range of 275-500° C., temperatures in the range of 275-375° C., temperatures in the range of 300-450° C., temperatures in the range of 350-450° C., and the like.

[0060] An example of the hydrogen purifier 144 is generally shown at 196 in FIG. 4. Unless otherwise noted, the hydrogen purifier 196 may include one or more components of other hydrogen purification devices and / or purification regions described herein. The hydrogen purifier 196 may include a shell or housing 198, which may include a first end plate or end frame 200 and a second end plate or end frame 202. The first and second end plates may be secured and / or compressed together and configured to define a sealed pressure vessel having an interior compartment 204 in which the hydrogen separation region is supported. The first and second end plates may include inlet ports, outlet ports, sweep gas ports, and by-product ports (not shown), similar to the hydrogen purifier 144.

[0061] The hydrogen purification apparatus 196 may include at least one foil microscreen assembly 205, which may be disposed between and / or secured to the first and second end plates. The foil microscreen assembly may include at least one hydrogen-selective membrane 206 and at least one microscreen structure 208, as shown in FIG. 5. The hydrogen-selective membrane may be configured to receive at least a portion of the mixed gas stream from the inlet port and separate the mixed gas stream into at least a portion of a permeate stream and at least a portion of a by-product stream. The hydrogen-selective membrane 206 may include a feed side 210 and a permeate side 212. At least a portion of the permeate stream is formed from a portion of the mixed gas stream that passes from the feed side to the permeate side, and the remaining portion of the mixed gas stream that remains on the feed side forms at least a portion of the by-product stream.

[0062] The one or more hydrogen-selective membranes may be metallurgically bonded to the microscreen structure 208. For example, the permeate side of the hydrogen-selective membrane may be metallurgically bonded to the microscreen structure. In some embodiments, the one or more hydrogen-selective membranes 206 (and / or the permeate side of the membrane) may be diffusion bonded to the microscreen structure to form a solid-state diffusion bond between the membrane and the microscreen structure. For example, the permeate side of the membrane and the microscreen structure may be contacted with each other and exposed to elevated temperatures and / or pressures to cause the surfaces of the membrane and the microscreen structure to intersperse over time.

[0063] In some embodiments, the microscreen structure may be covered with a metal layer or intermediate bonding layer that aids in diffusion bonding, such as a thin coating of nickel, copper, silver, gold, or other metal suitable for solid-state diffusion bonding and that (1) does not melt to a liquid phase below 700°C, and (2) does not form a low melting point alloy below 700°C upon diffusion into the hydrogen-selective membrane. The thin metal layer may be applied to the microscreen structure by a suitable deposition process (electrochemical plating, vapor deposition, sputtering, etc.) as a thin coating of the intermediate bonding layer on the surface of the microscreen structure that contacts the hydrogen-selective membrane. In other embodiments, the hydrogen-selective membrane may be secured to at least one membrane frame (not shown), which may be secured to a first end frame and a second end frame.

[0064] The microscreen structure 208 may include any suitable structure configured to support at least one hydrogen-selective membrane. For example, as shown in FIG. 6, the microscreen structure may include a non-porous planar sheet 213 having generally opposed faces 214 and 215 configured to provide support for a permeate side 212, and a plurality of apertures 216 forming a plurality of channels 217 extending between the faces to allow permeate flow through the microscreen structure. The apertures may be provided in the non-porous planar sheet by electrochemical etching, laser drilling, or other mechanical forming processes (such as stamping or die cutting). In some embodiments, as shown in FIG. 6, one or more of the apertures (or all of the apertures) may be provided in the non-porous planar sheet such that the longitudinal axis of the aperture or longitudinal axis of the channel is perpendicular to the plane of the non-porous planar sheet. The non-porous planar sheet may be of any suitable thickness, for example, between about 100 micrometers and about 200 micrometers.

[0065] In some embodiments, the microscreen structure 208 may include one or more perforated regions (or portions) 218 ​​that include a plurality of apertures, and one or more non-perforated regions (or portions) 219 that do not include (exclude) a plurality of apertures. Although only a few apertures 216 are shown in FIG. 6, the apertures 216 are distributed throughout the length and width of the perforated portions only. The perforated regions may be discrete or separated from one or more other perforated regions. The non-perforated regions 219 may include a perimeter region (or portion) 220 that forms a frame around the one or more perforated regions, and / or one or more border regions (or portions) 221 that separate or define two or more discrete portions of the perforated regions. That is, each perforated portion may be separated from other adjacent discrete perforated portions by at least one border portion that does not include a plurality of apertures.

[0066] The openings 216 may have any suitable pattern, shape and / or size. In some embodiments, the openings may be formed in one or more patterns that maximize the total open area while maintaining a high enough stiffness of the microscreen structure to prevent excessive deflection under pressure loads. The openings 216 may be circular as shown in FIG. 6, elongated circles as shown in FIG. 7, ovals as shown in FIG. 8, hexagons as shown in FIG. 9, triangles, squares, rectangles, octagons, and / or other suitable shapes. In some embodiments, the openings 216 in the perforated region may all be the same shape. In other embodiments, the openings 216 in the perforated region may be a suitable combination of two or more different shapes. The openings may be any suitable size. For example, if the openings are circular, their diameter may be within a range of about 0.003 inches to about 0.020 inches. Also, if the openings are oval shaped, the radius of the circular end of the oval may range from 0.001 inches to approximately 0.010 inches, and the length of the oval may be up to 10 times the radius. In some embodiments, the openings in the perforated region may all be the same size. In other embodiments, the openings 216 in the perforated region may be any suitable combination of two or more different sizes.

[0067] The non-porous planar sheet may comprise any suitable material. For example, the non-porous planar sheet may comprise stainless steel. The stainless steel may comprise 300 series stainless steel (e.g., stainless steel 303 (aluminum modified), stainless steel 304, etc.), 400 series stainless steel, 17-7PH, 14-8PH, and / or 15-7PH. In some embodiments, the stainless steel may comprise about 0.6% to about 3.0% aluminum by weight. In some embodiments, the non-porous planar sheet may comprise carbon steel, copper or copper alloy, aluminum or aluminum alloy, nickel, nickel-copper alloy, and / or a base metal plated with silver and / or nickel and / or copper. The base metal may comprise carbon steel or one or more of the stainless steels described above.

[0068] The hydrogen-selective membrane 206 may be sized larger than the perforated area or field of the microscreen structure such that a peripheral portion 222 of the hydrogen-selective membrane contacts one or more non-perforated areas 219 of the microscreen structure when the hydrogen-selective membrane is metallurgically bonded to the microscreen structure. In some embodiments, a single hydrogen-selective membrane may be metallurgically bonded to a single microscreen structure, as shown in FIG. 5. In other embodiments, two or more hydrogen-selective membranes 206 may be metallurgically bonded to a single microscreen structure 208. For example, two, three, four, five, six, seven, eight, nine, ten or more hydrogen-selective membranes 206 may be metallurgically bonded to a single microscreen structure 208. FIG. 10 illustrates an example of a foil microscreen assembly 205 having six hydrogen-selective membranes 206 metallurgically bonded to a single microscreen structure 208. FIG. 12 illustrates an example of a foil microscreen assembly 205 having two hydrogen-selective membranes 206 metallurgically bonded to a single microscreen structure 208. FIG. 13 shows an example of a foil microscreen assembly 205 having four hydrogen-selective membranes 206 metallurgically bonded to a single microscreen structure 208 .

[0069] When two or more hydrogen-selective membranes 206 are metallurgically bonded to the microscreen structure, the microscreen structure may include two or more discrete perforated regions 218 separated by one or more non-perforated regions 219. In some embodiments, the perforated regions 218 may be the same size as the other perforated regions 218. For example, FIG. 11 shows six discrete perforated regions 218 that are approximately the same size. In other embodiments, one or more perforated regions 218 may be smaller and / or larger in size than the other perforated regions 218. The hydrogen-selective membrane 206 may be metallurgically bonded to each perforated region as shown in FIG. 10. Alternatively or additionally, the hydrogen-selective membrane may be metallurgically bonded to two or more discrete perforated regions 218. The hydrogen-selective membrane 206 may be sized such that a peripheral portion 222 of the membrane contacts one or more non-perforated regions 219 when the membrane is metallurgically bonded to the one or more perforated regions 218.

[0070] The microscreen structure 208 may be sized to be contained (e.g., entirely contained) within the open area of ​​the transmission frame and / or supported by the membrane support structure within the open area, as shown in FIG. 5. That is, the microscreen structure may be sized to not contact the peripheral shell of the transmission frame when the microscreen structure and transmission frame are secured or compressed against the first and second end frames. Instead, the microscreen structure may be supported by and / or secured to a non-porous peripheral wall portion or frame (not shown) (such as the peripheral shell of the transmission frame). When the microscreen structure is secured to a non-porous peripheral wall portion, the microscreen structure may be referred to as a "porous central region portion." Other examples of microscreen structures are disclosed in U.S. Pat. No. 6,399,323, the entire disclosure of which is incorporated herein by reference for all purposes.

[0071] The hydrogen purifier 196 may include a plurality of plates or frames 224 disposed between and secured to a first end frame and / or a second end frame. The frames may include any suitable structure and / or may be any suitable shape, such as square, rectangular, or circular. For example, as shown in FIG. 4, the frame 224 may include a perimeter shell 226 and at least one first support member 228. The perimeter shell may define an open area 230 and a frame plane 232. Further, as shown in FIG. 4, the perimeter shell 226 may include opposing first and second sides 234 and 236, and opposing third and fourth sides 238 and 240.

[0072] The first support member 228 may include any suitable structure configured to support the first portion 242 of the foil microscreen assembly 205, as shown in FIG. 4. For example, the first support members of the plurality of frames may be coplanar with each other (or with other first support members of other frames of the plurality of frames) within the first support plane 244 to support the first portion 242 of the hydrogen-selective membrane, as shown in FIG. 4. That is, the first support members of each frame of the plurality of frames may be a mirror image of the first support members of other frames of the plurality of frames. The first support members may have any suitable orientation with respect to the frame plane 232. For example, the first support plane 244 may be perpendicular to the frame plane, as shown in FIG. 4. Alternatively, the first membrane support plane may intersect but not be perpendicular to the frame plane 232.

[0073] In some embodiments, the frame 224 may include a second support member 246 and / or a third support member 248, which may include any suitable structure configured to support the second portion 250 and / or the third portion 252 of the foil microscreen assembly 205, as shown in FIG. 4. For example, the second support members of the plurality of frames may be coplanar with each other (or with other second support members of the plurality of frames) within a second support plane 254 to support the second portion 250 of the foil microscreen assembly. Additionally, the third support members of the plurality of frames may be coplanar with each other (or with other third support members of the plurality of frames) within a third support plane 256 to support the third portion 252 of the foil microscreen assembly. That is, the second support member of each frame of the plurality of frames may be a mirror image of the second support member of the other frame of the plurality of frames, while the third support member of each frame of the plurality of frames may be a mirror image of the third support member of the other frame of the plurality of frames. The second support plane and / or the third support plane may have any suitable orientation with respect to the frame plane 232. For example, the second support plane 254 and / or the third support plane 256 can be perpendicular to the frame plane, as shown in Figure 4. Alternatively, the second support surface and the third support plane can intersect but not be perpendicular to the frame plane 232.

[0074] The second support member 246 and / or the third support member 248 may have any suitable orientation relative to the first support member 228. For example, the first support member 228 may extend into the open area 230 from the third side 238 of the surrounding shell 226, the second support member 246 may extend into the open area from the fourth side 240 (opposite the third side) of the surrounding shell, and the third support member 248 may extend into the open area from the third side. Alternatively, the first support member, the second support member, and / or the third support member may extend into the open area from the same side of the surrounding shell, such as the first side, the second side, the third side, or the fourth side. In some embodiments, the first support member, the second support member, and / or the third support member may extend into the open area from the first side and / or the second side (opposite the first side) of the surrounding shell.

[0075] The first support member, the second support member, and / or the third support member may be in the form of, for example, one or more protrusions or fingers 258 attached to and / or formed with the perimeter shell. The protrusions may extend from the perimeter shell in any suitable direction. The protrusions may be the full thickness of the perimeter shell or may be less than the full thickness of the perimeter shell. The protrusions of each of the frames 224 may be compressed against the foil microscreen assembly to secure the assembly in place. That is, the protrusions of the frames 224 may be stacked extensions of the end frames in the first and / or second membrane support planes to support the foil microscreen assembly. In some embodiments, the protrusions 258 may include one or more receivers or openings (not shown) configured to receive at least one fastener (not shown) to secure the frame 224 to the first and / or second end frames.

[0076] The frame 224 may include at least one feed frame 260, at least one transmission frame 262, and a number of gaskets or gasket frames 264, as shown in Figure 4. The feed frame 260 may be disposed between one of the first and second end frames and at least one foil microscreen assembly 205, or between two foil microscreen assemblies 205. The feed frame may include a feed frame peripheral shell 266, a feed frame inlet conduit 268, a feed frame outlet conduit 270, a feed frame open area 272, and at least a first feed frame support member 274, as shown in Figure 4. In some embodiments, the feed frame may include a second feed frame support member 276 and / or a third feed frame support member 278.

[0077] The feed frame perimeter shell 266 may include any suitable structure. For example, the feed frame perimeter shell may include a first section or first perimeter shell 280 and a second section or second perimeter shell 282 as shown in FIG. 14. Note that the components in FIG. 14 are exaggerated for illustrative purposes and may not reflect the relative dimensions of the components. The first and second sections may be first and second halves of the perimeter shell or any suitable portion of the perimeter shell. Additionally, the first and / or second sections may include channels or grooves (not shown) in any suitable interrelated relationship, such as being offset from one another. The first and second sections 280 and 282 may be joined via any suitable method to form an airtight seal between the sections. For example, a feed frame gasket 284 may be used between the sections. Alternatively, the first and second sections may be brazed to one another or a layering metal may be used to bond the first and second sections, as described in U.S. Patent No. 5,399,633, the entire disclosure of which is incorporated herein by reference for all purposes.

[0078] Further, the feed frame peripheral shell 266 may have any suitable dimensions configured to support other components of the hydrogen purification apparatus 196. For example, the feed frame peripheral shell may be sized to support the peripheral shells of the permeation frames 262 and their membrane support structures 286 along a plurality of feed frame support planes 288. For example, the peripheral shell 266 may have a width 290 that is large compared to a width 292 of the peripheral shell of the permeation frames 262 such that at least a portion 294 of the peripheral shell supports a portion 296 of the membrane support structure 286, as shown in FIG. 14. That is, the feed frame peripheral shell may secure the membrane support structure in place and act as a stop for that support structure. The feed frame support plane may have any suitable orientation with respect to the feed frame plane 300. For example, the feed frame support plane may be perpendicular to the feed frame plane, as shown in FIG. 14. Alternatively, the feed frame support plane may intersect the feed frame plane 300 but not perpendicular to the feed frame plane 300.

[0079] A feed frame inlet conduit may be formed on the feed frame peripheral shell and / or configured to receive at least a portion of the mixed gas flow from the inlet port. A feed frame outlet conduit 270 may be formed on the feed frame peripheral shell and / or configured to receive the remaining portion of the mixed gas flow that leaves the feed side 210 of the hydrogen-selective membrane 206. A feed frame open area 272 may be disposed between the feed frame inlet conduit and the feed frame outlet conduit. The feed frame peripheral shell 266 may include a number of grooves or channels (not shown) that fluidly connect the inlet and outlet conduits with the feed frame open area. The channels may be formed on the peripheral shell via any suitable method and / or may have any suitable orientation, such as an oblique orientation, that may cause mixing within the feed frame open area 260.

[0080] The first feed frame support member, the second feed frame support member, and / or the third feed frame support member may include any suitable structure configured to support the first, second, and / or third portions of at least one hydrogen-selective membrane and / or may be a mirror image of the first, second, and / or third support members of the other frames, as described above. Additionally, the first feed frame support member, the second feed frame support member, and / or the third feed frame support member may include any suitable structure configured to change the direction of flow of at least a portion of the mixed gas stream as it flows across the feed frame opening area between the inlet and outlet conduits. The first feed frame support member and / or the second feed frame support member may also be configured to promote turbulence or mixing within the feed frame opening area. For example, without the first feed frame support member and / or the second feed frame support member, the flow of at least a portion of the mixed gas stream across the feed frame opening area between the inlet and outlet conduits may move in at least a first direction (not shown). The first feed frame membrane support structure and / or the second feed frame membrane support structure may be configured to redirect the flow of at least a portion of the mixed gas stream from at least a first direction to at least a second direction (not shown) that is different from the first direction.

[0081] The first feed frame support member, the second feed frame support member, and / or the third feed frame support member may be in the form of, for example, at least one feed frame protrusion or finger 302 attached to and / or formed with the feed frame peripheral shell. The feed frame protrusion may extend from the peripheral shell in any suitable direction. For example, the feed frame protrusion may extend from the feed frame peripheral shell in a direction that is generally perpendicular (and / or generally parallel) to the direction in which at least a portion of the mixed gas flow flows from the inlet conduit toward the feed frame opening area. For example, if the flow of the mixed gas flow from the inlet conduit toward the feed frame opening area is along a generally horizontal direction, the feed frame protrusion may extend from the feed frame peripheral shell in a generally perpendicular and / or horizontal direction.

[0082] The transmission frame 262 may be positioned such that at least one foil microscreen assembly is disposed between the transmission frame and one of the first and second end frames, or between two foil microscreen assemblies. The transmission frame may include a transmission frame peripheral shell 304, a transmission frame outflow conduit 306, a transmission frame open area 308, and a membrane support structure 286, as shown in FIG.

[0083] The transmission frame perimeter shell may include any suitable structure. For example, the transmission frame perimeter shell may include a first section or first perimeter shell 310 and a second section or second perimeter shell 312 as shown in FIG. 14. The first and second sections may be first and second halves of the perimeter shell or any suitable portion of the perimeter shell. Additionally, the first and / or second sections may include channels or grooves (not shown) in any suitable interrelationship, such as being offset from one another. The first and second sections 310 and 312 may be joined via any suitable method to form an airtight seal between the sections. For example, a transmission frame gasket 314 may be used between the sections. The transmission frame gasket may be configured such that when the transmission frame 262 is secured to the first and second end frames, as shown in FIG. 14 and discussed further below, the thickness 316 of the transmission frame perimeter shell matches or substantially matches (is the same as or is substantially the same as) the thickness 318 of the membrane support structure.

[0084] Alternatively, the first and second sections may be brazed to one another or a layer-forming metal may be used to bond the first and second sections, as described in U.S. Patent No. 5,399,633, the entire disclosure of which is incorporated herein by reference for all purposes.

[0085] In some embodiments, the transmissive frame peripheral shell 304 may include a first section 320, a second section 322, and a third section 324 disposed between the first and second sections, as shown in FIG. 16. These sections may be the first, second, and third sections of the peripheral shell, or may be any portion of the peripheral shell. Additionally, the first, second, and / or third sections may include channels or grooves (not shown) in any suitable interrelated relationship, such as being offset from one another. Note that the components in FIG. 16 are exaggerated for illustrative purposes and may not reflect the relative dimensions of these components.

[0086] The first section 320, the second section 322, and the third section 324 may be joined by any suitable method that forms an airtight seal between the sections. For example, a transmission frame gasket 326 may be used between the sections. The transmission frame gasket may be configured such that the thickness 316 of the transmission frame surrounding shell matches or substantially matches (is the same as or is substantially the same as) the thickness 318 of the membrane support structure when the transmission frame 262 is secured to the first and second end frames, as shown in FIG. 14. Alternatively, the first section, the second section, and / or the third section may be brazed together, or a layered metal may be used to join the first section, the second section, and / or the third section, as described in U.S. Patent No. 5,399,633, the entire disclosure of which is incorporated herein by reference for all purposes.

[0087] Outlet conduit 306 may be formed on the permeate frame peripheral shell 282 and may be configured to receive a permeate flow from the membrane support structure 286, the permeate frame open area 308, and / or the hydrogen-selective membrane. The peripheral shell 282 may include a number of grooves or channels (not shown) that place the outlet conduit 284 in fluid communication with the permeate frame open area and / or the membrane support structure. The channels may be formed on the peripheral shell 282 via any suitable method and / or may have any suitable orientation, such as an angled orientation.

[0088] The membrane support structure 286 may include any suitable structure configured to support at least one foil microscreen assembly, such as a first portion, a second portion, a third portion, and / or other portions of the foil microscreen assembly. In some embodiments, the membrane support structure may include a first support member, a second support member, and / or a third support member (not shown) similar to one or more other frames. Alternatively, the membrane support structure 286 may include one or more membrane support plates 328, as shown in FIG. 14. The membrane support plate may span any suitable portion of the aperture area, such as at least a majority of the aperture area. Additionally, the membrane support plate may be solid, flat, or planar, perforated or non-perforated (having no perforations or holes), non-ridged and / or non-protruding (having no ridges and / or non-protruding), and / or incompressible (or substantially incompressible). Additionally, the membrane support plate may not be attached (having no attachments) to the transmission frame surrounding shell. That is, the feed frame, when secured to the first and second end plates, may only secure the membrane support structure in place within the open area of ​​the transmission frame peripheral shell. Further, the membrane support plate may be made of any suitable material, such as stainless steel.

[0089] The membrane support plate 328 may include a first surface (or face) 330 and an opposing second surface (opposite face) 332, as shown in FIG. 14. One or both surfaces of the membrane support plate may be free of or free of any or all of the grooves, ridges, protrusions, etc., as shown in FIG. 17. In some embodiments, one or both surfaces of the membrane support plate 328 may include a plurality of microgrooves 334, as shown in FIG. 18, where the microgrooves may include any suitable structure that provides one or more flow paths for the permeate flow. When the membrane support plate 328 includes surface microgrooves, the plate may be referred to as a "surface grooved plate." The microgrooves may have any suitable orientation, such as being parallel to one another. Additionally, the microgrooves 334 may extend from a first end 336 to an opposing second end 338 (or from a third end to an opposing fourth end) of the membrane support plate, as shown in FIG. 18. Alternatively, one or more microgrooves may extend from the first end to just short of the second end, from the second end to just short of the first end, between the first end and the second end but not including the first end and the second end, etc. Further, the microgrooves 334 may be present only on the first surface, only on the second surface, or on both the first and second surfaces. Further, the microgrooves may be included along the entire length or width of the membrane support plate (as shown in FIG. 18), or may be present along any suitable portion of the length or width, such as 25%, 50%, or 75% of the length or width.

[0090] The microgrooves 334 may have any suitable dimensions. For example, the microgrooves may have a width between 0.005 inches and 0.020 inches (or preferably between 0.010 and 0.012 inches) and a depth between 0.003 and 0.020 inches (or preferably between 0.008 and 0.012 inches). The microgrooves may be spaced apart by any suitable distance, such as 0.003 to 0.020 inches (or preferably 0.003 to 0.007 inches). The microgrooves may be provided by any suitable method, such as chemical etching, machining, etc.

[0091] In some embodiments, as shown in FIG. 14, the membrane support structure 286 may include a single support plate 339 having opposing sides (one or both sides having micro-grooves 334). Alternatively, the membrane support structure may include a first membrane support plate 340 and a second membrane support plate 342, as shown by dashed lines in FIG. 14. The first membrane support plate may include a first side 344 and an opposing second side 346. The second membrane support plate 342 may include a first side 348 and an opposing second side 349. The first side of the first membrane support plate and / or the second membrane support plate may or may not include micro-grooves 334. Furthermore, the second side of the first membrane support plate and the second side of the second membrane support plate may face each other. That is, the first membrane support plate and the second membrane support plate may be stacked in the membrane support structure such that the second side of the first membrane support plate faces the second side of the second membrane support plate and / or vice versa. In some embodiments, the second side of the first membrane support plate may contact the second side of the second membrane support plate.

[0092] In some embodiments, the membrane support structure may include a third membrane support plate 350, which may be disposed between the first and second membrane support plates, as shown in FIG. 19. The components in FIG. 19 are exaggerated for illustrative purposes and may not reflect the relative dimensions of these components. The membrane support structure may include a first membrane support plate, a second membrane support plate, and a third membrane support plate stacked such that the third membrane support plate contacts the second side of the first membrane support plate and / or the second membrane support plate. When the third membrane support plate is disposed between the first membrane support plate and the second membrane support plate, the third membrane support plate may be referred to as a "center plate." The third membrane support plate may be free of microgrooves on one or both sides thereof. The first membrane support plate, the second membrane support plate, and the third membrane support plate may have any suitable dimensions. For example, the first membrane support plate and the second membrane support plate may be 0.060 inches, while the third membrane support plate may be 0.105 inches.

[0093] As described above, the permeate frame gaskets 314 and / or 326 may be configured such that the thickness of the permeate frame matches the thickness of the membrane support structure when the permeate frame is secured to the first and second end frames and / or compressed. These gaskets may provide a large thickness compared to the thickness of the membrane support structure before compression. If a flexible graphite gasket is used as the permeate frame gasket with a compression limit of 15 to 50%, the permeate frame gasket may have a thickness that provides a predetermined final thickness within these compression limits before compression. If the permeate frame includes such a gasket, the permeate frame may be referred to as a "self-regulating permeate frame." If the self-regulating permeate frame is compressed during assembly by compression through the feed frame (such as under a compression of 1000 to 2000 psi) to form an airtight seal between the feed frame and the hydrogen-selective membrane, the compressive force of the feed frame against the permeate frame may cease when the feed frame contacts the hydrogen-selective membrane, forming a substantially incompressible set or stack of components together with the microscreen structure and the membrane support structure.

[0094] As an example, if the membrane support structure has a thickness of 0.257 inches, the transmission frame would ideally have a thickness of exactly or about 0.257 inches. The transmission frame surrounding shell may include two sections, each 0.120 inches thick, for example, and the transmission frame gasket may be configured to be 0.017 inches thick after compression. For example, a transmission frame gasket that is 0.030 inches thick before compression may be compressed to within its compression limits to a thickness of 0.017 inches after compression, thereby matching the thickness of the transmission frame to the thickness of the membrane support structure. Although the membrane support structure 286 is shown to include a membrane support plate 328, the membrane support structure may also include a wire mesh and / or a metal sheet with perforations (perforations) (not shown).

[0095] As shown in FIG. 4, the frame 224 may also include a gasket or gasket frame 264. The gasket frame may include any suitable structure configured to provide a fluid-tight interface with other frames, such as between the first and second end plates 200 and 202 and the feed frame 260, between the feed frame 260 and the foil microscreen assembly 205, between the foil microscreen assembly and the permeate frame 262, etc. An example of a suitable gasket for the gasket frame 264 includes a flexible graphite gasket. Another example of a suitable gasket material is THERMICULITE® 866 sold by Flexitallic LP, Inc. (Deer Park, Texas). Although the frame 224 is shown as including two feed frames 260 and a single permeate frame 262, the frame may include any suitable number of feed frames and permeate frames. Additionally, although the hydrogen purification device 196 is shown as including two hydrogen-selective membranes 206, the device may include any suitable number of these membranes.

[0096] Although one or more of the frames 224 are shown including protrusions that extend only orthogonally or only horizontally, the frames may additionally or alternatively include protrusions that extend horizontally, orthogonally, and / or diagonally, or in other suitable directions. Further, although one or more of the frames 224 are shown including three protrusions, the frames may include one, two, four, five, or more protrusions. Further, although one or more of the frames 224 are shown including protrusions that are coplanar in a first support plane, a second support plane, and / or a third support plane, the frames may additionally or alternatively include protrusions that are coplanar in a fourth support plane, a fifth support plane, or more support planes.

[0097] Another example of a hydrogen purification device 144 is shown generally at 396 in Figure 20. Unless otherwise indicated, hydrogen purification device 396 may include one or more components of other hydrogen purification devices and / or purification sections of this disclosure.

[0098] Hydrogen purifier 396 is similar in many respects to hydrogen purifier 196, but has a different shaped frame, no support membrane, a different sized foil microscreen assembly, and fewer gasket frames, as described further below. Components or parts of hydrogen purifier 396 correspond to components or parts of hydrogen purifier 196 and are labeled with similar reference numbers in FIG. 20 with the format "3XX" instead of "1XX" and "4XX" instead of "2XX." Thus, features 398, 400, 402, 404, 405, 406, 408, 424, 426, 434, 436, 438, 440, 460, 462, 464, etc. may be identical or substantially identical to their respective counterparts in the hydrogen purification apparatus 196, i.e., features 198, 200, 202, 204, 205, 206, 208, 224, 226, 234, 236, 238, 240, 260, 262, 264, etc.

[0099] The hydrogen purification apparatus 396 may include a shell or housing 398 that may include a first end plate or end frame 400 and a second end plate or end frame 402. The first end plate and the second end plate may be configured to be secured and / or compressed together to define a sealed pressure vessel having an interior compartment 404 in which the hydrogen separation region is supported.

[0100] The hydrogen purifier 396 may also include at least one foil microscreen assembly 405 that may be disposed between and / or secured to the first and second end plates. The foil microscreen assembly may include at least one hydrogen-selective membrane 406 and at least one microscreen structure 408. The one or more hydrogen-selective membranes may be metallurgically bonded to the microscreen structure 408. For example, the one or more hydrogen-selective membranes 406 may be diffusion bonded to the microscreen structure to form a solid-state diffusion bond between the membrane and the microscreen structure. The foil microscreen assembly 405 is sized to fit within the open area of ​​the transmission frame and thus has a reduced length and width compared to the foil microscreen assembly 205.

[0101] The hydrogen purifier 396 may also include a plurality of plates or frames 424 disposed between and secured to the first and / or second end frames. The frame 424 may include a perimeter shell 426. The perimeter shell may define an open area 430. Further, the perimeter shell 426 may include opposing first and second sides 434, 436, and opposing third and fourth sides 438, 440. Unlike the frame 224 of the hydrogen purifier 196, the frame 424 does not include support members.

[0102] Frame 424 may include at least one feed frame 460, at least one transmission frame 462, and a number of gaskets or gasket frames 464. The feed frame 460 may be disposed between one of the first and second end frames and at least the foil microscreen assembly 405, or between two foil microscreen assemblies 405. The feed frame may include at least substantially similar components as feed frame 260, such as a feed frame peripheral shell, a feed frame inlet conduit, a feed frame outlet conduit, and / or a feed frame opening area.

[0103] The transmission frame 462 may be positioned such that at least one foil microscreen assembly is disposed between one of the first and second end frames and the transmission frame or between two foil microscreen assemblies. The transmission frame may include at least substantially similar components as the transmission frame 262, such as a transmission frame peripheral shell, a transmission frame outflow conduit, a transmission frame aperture area, and / or a membrane support structure.

[0104] Frame 424 may also include a gasket or gasket frame 464. The gasket frame may include any suitable structure configured to provide a fluid-tight interface between different frames, such as between first end plate 400 and second end plate 402 and the feed frame, and / or between feed frame 460 and the foil microscreen assembly 405. Unlike hydrogen purifier 196, hydrogen purifier 396 does not include a gasket frame 464 between the foil microscreen assembly and the permeate frame 462. Similar to hydrogen purifier 196, the width of the feed frame and gasket frame is greater than the width of the permeate frame (or the open area of ​​the feed frame and gasket frame is less than the open area of ​​the permeate frame), such that the extra width covers the edges of the foil microscreen assembly to eliminate or minimize leakage from the feed side to the permeate side and vice versa (see, e.g., FIG. 14, which shows how the extra width of the feed frame and gasket frame covers the edges of the foil microscreen assembly). In some embodiments, the extra width corresponds to the width of the perimeter (non-perforated) portion of the microscreen structure of the foil microscreen assembly.

[0105] The hydrogen purification apparatus and / or components thereof (e.g., foil microscreen assemblies) of the present disclosure may include one or more of the following: a first end frame and a second end frame including an inlet port configured to receive a mixed gas flow including hydrogen gas and other gases; a first end frame and a second end frame including an outlet port configured to receive a permeate stream including a higher concentration of hydrogen gas and / or a lower concentration of another gas relative to the mixed gas stream; o a first end frame and a second end frame including a by-product port configured to receive a by-product stream including at least a majority of the other gas; at least one foil microscreen assembly disposed between and secured to a first end frame and a second end frame; at least one hydrogen-selective membrane disposed between and secured to a first end frame and a second end frame; at least one hydrogen-selective membrane having a feed side and a permeate side, where at least a portion of the permeate stream is formed from a portion of the mixed gas stream passing from the feed side to the permeate side, and where a remaining portion of the mixed gas stream remaining in the feed side forms at least a portion of the by-product stream; at least one hydrogen-selective membrane metallurgically bonded to the at least one microscreen structure; a permeate side of at least one hydrogen-selective membrane metallurgically bonded to at least one microscreen structure; at least one hydrogen-selective membrane diffusion bonded to the at least one microscreen structure; a permeate side of at least one hydrogen-selective membrane diffusion bonded to at least one microscreen structure; o at least one microscreen structure disposed between the at least one hydrogen-selective membrane and the at least one permeation frame; o at least one microscreen structure configured to support at least one hydrogen-selective membrane; o At least one microscreen structure including substantially opposing surfaces configured to provide support to the permeate side; o at least one microscreen structure including a plurality of flow channels extending between opposing surfaces; at least one microscreen structure sized so as not to contact a peripheral shell of the at least one transmission frame; o at least one microscreen structure sized so as not to contact the surrounding shell when the at least one microscreen structure and the at least one transmission frame are secured to the first end frame and the second end frame; at least one microscreen structure provided with a non-porous planar sheet having a plurality of openings forming a plurality of flow channels; o a non-porous planar sheet including substantially opposed surfaces configured to provide support to the permeate side; a non-porous planar sheet including at least one peripheral portion that is free of apertures; o a non-porous planar sheet provided with two or more discrete portions having apertures; at least one microscreen structure comprising a non-porous metal sheet having a plurality of openings therein forming a plurality of flow channels; o a non-porous metal sheet defining a plane (the openings in the non-porous sheet having axes perpendicular to the plane); ○ Circular openings in a non-porous sheet; ○ An elongated circular opening in a non-porous sheet; ○ Oval-shaped openings in a non-porous sheet; ○ Hexagonal openings in a non-porous sheet; ○ Non-porous metal sheets, including stainless steel; ○ Non-porous metal sheets including 300 series stainless steels; ○ Non-porous metal sheets including 400 series stainless steels; o a non-porous metal sheet comprising stainless steel having about 0.6% to about 3.0% by weight aluminum; ○ Non-porous metal sheet containing one or more nickel alloys; a non-porous metal sheet comprising one or more nickel alloys having a nickel-plated surface; a non-porous metal sheet comprising one or more nickel alloys with copper; o one or more discrete portions separated from adjacent discrete portions by at least one boundary portion that does not include an aperture; ○ A hydrogen-selective membrane metallurgically bonded to different discrete sections; o a hydrogen-selective membrane sized larger than the discrete portions such that a peripheral portion of the hydrogen-selective membrane contacts one or more portions of a non-porous planar sheet that does not contain apertures; a plurality of frames secured to the first and second end frames and disposed between the first and second end frames and the at least one hydrogen-selective membrane; a plurality of frames including at least one permeation frame disposed between at least one hydrogen-selective membrane and a second end frame; ○ At least one transparent frame including a surrounding shell; o at least one permeation frame formed in the surrounding shell and including an outlet conduit configured to receive at least a portion of the permeate flow from the at least one hydrogen-selective membrane; o At least one transparent frame including an aperture area surrounded by a surrounding shell; ○ at least one transmission frame including at least one membrane support structure; ○ at least one membrane support structure spanning at least a majority of the aperture area; o at least one membrane support structure configured to support at least one hydrogen-selective membrane; o at least one membrane support structure including a single membrane support plate including a first side and a second side opposite the first side; o a first surface and / or a second surface having a plurality of microgrooves configured to provide a flow path for at least a portion of the permeate stream; ○ the first surface and / or the second surface are not provided with microgrooves; ○ at least one membrane support structure including a first membrane support plate and a second membrane support plate; ○ a first membrane support plate and a second membrane support plate that are not perforated (do not contain through holes); a first membrane support plate having a first surface with a plurality of microgrooves configured to provide a flow path for at least a portion of the permeate stream and a second membrane support plate; a first membrane support plate and a second membrane support plate having a second surface opposite the first surface; ○ a first membrane support plate and a second membrane support plate stacked in at least one membrane support structure; a first membrane support plate and a second membrane support plate stacked in at least one membrane support structure such that a second side of the first membrane support plate faces a second side of the second membrane support plate; ○ Incompressible first and second membrane support plates; ○ Flat first and second membrane support plates; at least one feed frame disposed between the first end frame and the at least one hydrogen-selective membrane; ○ At least one feed frame including a surrounding shell; at least one supply frame including an inlet conduit formed in a peripheral shell of the at least one supply frame; ○ at least one supply frame including an inlet conduit configured to receive at least a portion of the mixed gas flow from the inlet port; at least one feeding frame including an outlet conduit formed in a peripheral shell of the at least one feeding frame; o at least one feed frame including an outlet conduit configured to receive a remainder of at least a portion of the mixed gas stream remaining on the feed side of the at least one hydrogen-selective membrane; ○ at least one feed frame including a feed frame opening area surrounded by a feed frame peripheral shell and disposed between the inlet conduit and the outlet conduit; o a peripheral shell of at least one feed frame sized such that the peripheral shell of the at least one feed frame supports the peripheral shell of the at least one permeation frame and a portion of the at least one membrane support structure; o a peripheral shell of at least one feed frame sized such that the peripheral shell of the at least one feed frame supports the peripheral shell of the at least one permeation frame and a portion of the at least one membrane support structure along a plurality of support planes perpendicular to the frame plane of each frame of the plurality of frames; ○ at least one membrane support structure including a third membrane support plate; ○ a third membrane support plate disposed between the first membrane support plate and the second membrane support plate; ○ Incompressible third membrane support plate; ○ A flat third membrane support plate; ○ A non-perforated (contains no through holes) third membrane support plate; ○ a third membrane support plate not provided with microgrooves; o a peripheral shell of the transparent frame comprising a first peripheral shell and a second peripheral shell; a peripheral shell of the transmission frame including a gasket disposed between the first peripheral shell and the second peripheral shell; o A gasket configured such that the thickness of the transmission frame surrounding shell matches the thickness of the membrane support structure; o a gasket configured such that a thickness of the transmission frame surrounding shell matches a thickness of the membrane support structure when the transmission frame is secured to the first end frame and the second end frame; o A transparent frame perimeter shell including a first perimeter shell, a second perimeter shell, and a third perimeter shell; a transmission frame perimeter shell including a first gasket disposed between the first perimeter shell and the second perimeter shell; o a transmission frame perimeter shell including a second gasket disposed between the second perimeter shell and the third perimeter shell; o a first gasket and a second gasket configured such that the thickness of the permeable frame surrounding shell matches the thickness of the membrane support structure; o first and second gaskets configured such that a thickness of the transmission frame surrounding shell matches a thickness of the membrane support structure when the transmission frame is secured to the first and second end frames; a first membrane support plate and a second membrane support plate having opposing first and second ends, respectively; ○ a plurality of microgrooves extending from the first end to the second end; Multiple parallel micro-grooves. [Industrial Applicability]

[0106] The present disclosure includes hydrogen purification apparatus, and components thereof, and may be used in fuel processing and other industries where hydrogen gas is refined, produced, and / or utilized.

[0107] The above disclosure encompasses multiple distinct inventions having independent utility. While each of these inventions is disclosed in its preferred form, the specific embodiments thereof disclosed and described herein are susceptible of many variations and are not to be considered limiting. The subject matter of the invention includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions, and / or properties disclosed herein. Similarly, when any claim recites "a" or "first" element or the equivalent thereof, such claim is to be understood as including the incorporation of one or more such elements without requiring or excluding two or more such elements.

[0108] Inventions embodied in various combinations and subcombinations of features, functions, elements, and / or properties may be claimed through the presentation of new claims in the related application, and such new claims, whether they relate to different inventions or to the same invention, and whether they are different, broader, narrower, or the same in scope as the original claims, shall be considered to fall within the scope of the inventive subject matter of this disclosure. [Explanation of symbols]

[0109] 196 Hydrogen Purification Equipment 198 Case 200 First end plate 202 Second end plate 204 Internal Compartment 205 Foil Microscreen Assembly 206 Hydrogen-selective membrane 208 Microscreen Structure 210 Supply Side 212 Transmission side 213 Non-porous flat sheet 216 Aperture 217 Channel 218 Drilling area 219 Unperforated area 224 frames 226 Surrounding Shell 228 First support member 230 Opening area 246 Second support member 248 Third support member 258 Protrusion 260 Supply Frame 262 Transparent Frame 264 Gasket Frame 266 Surrounding Shell 268 Supply Frame Inlet Conduit 270 Supply Frame Outlet Conduit 272 Supply Frame Opening Area 274 First supply frame support member 276 Second supply frame support member 278 Third supply frame support member 282 Transparent Frame Surrounding Shell 284 Supply Frame Gasket 286 Membrane support structure 302 Protrusion 304 Transparent Frame Surrounding Shell 306 Permeable frame outflow duct 308 Transmission Frame Aperture Area 314 Transparent frame gasket 326 Transparent frame gasket 328 Membrane Support Plate 334 Micro Groove 339 Support Plate 340 First membrane support plate 342 Second membrane support plate 350 Third membrane support plate 396 Hydrogen Purification Equipment 398 Case 400 First End Plate 402 Second End Plate 404 Internal Compartment 405 Foil Microscreen Assembly 406 Hydrogen-selective membrane 408 Microscreen Structure 424 frames 426 Surrounding Shell 430 Opening area 460 Supply Frame 462 Transparent Frame 464 Gasket Frame

Claims

1. A first end frame and a second end frame, an inlet port configured to receive a mixed gas flow including hydrogen gas and other gases; an outlet port configured to receive a permeate stream having a higher concentration of hydrogen gas and / or a lower concentration of another gas relative to the mixed gas stream; a by-product port configured to receive a by-product stream comprising at least a majority of the other gas; and at least one foil microscreen assembly disposed between and secured to the first end frame and the second end frame, at least one hydrogen-selective membrane having a feed side and a permeate side, wherein at least a portion of the permeate stream is formed from a portion of the mixed gas stream passing from the feed side to the permeate side, and a remaining portion of the mixed gas stream remaining on the feed side forms at least a portion of the by-product stream; at least one foil microscreen assembly comprising: at least one microscreen structure including a non-porous planar sheet having a plurality of openings defining a plurality of flow passages, the non-porous planar sheet including substantially opposed surfaces configured to support the permeate side, the plurality of flow passages extending between the surfaces, and the at least one hydrogen-selective membrane being metallurgically bonded to the at least one microscreen structure; a plurality of frames disposed between the first and second end frames and the at least one foil microscreen assembly and secured to the first and second end frames, each frame including a peripheral shell defining an open area.

2. The hydrogen purification apparatus of claim 1 , wherein the plurality of openings are disposed in the non-porous planar sheet such that at least a periphery of the non-porous planar sheet is free of the plurality of openings.

3. The hydrogen purification apparatus of claim 2 , wherein the non-porous planar sheet includes two or more discrete portions having the plurality of apertures disposed therein.

4. 4. The hydrogen purification apparatus of claim 3, wherein each discrete portion of the two or more discrete portions is separated from an adjacent discrete portion of the two or more discrete portions by at least one boundary portion that is not provided with the plurality of openings.

5. 4. The hydrogen purification apparatus of claim 3, wherein the at least one hydrogen-selective membrane comprises two or more hydrogen-selective membranes, each hydrogen-selective membrane of the two or more hydrogen-selective membranes being metallurgically bonded to a respective different one of the two or more discrete portions.

6. 6. The hydrogen purifier of claim 5, wherein each hydrogen-selective membrane of the two or more hydrogen-selective membranes has a size larger than a corresponding discrete portion such that a peripheral portion of the hydrogen-selective membrane contacts one or more portions of the non-porous planar sheet that are not provided with the plurality of apertures.

7. 10. The hydrogen purification apparatus of claim 1, wherein the at least one hydrogen-selective membrane is diffusion bonded to the at least one microscreen structure.

8. A first end frame and a second end frame, an inlet port configured to receive a mixed gas flow including hydrogen gas and other gases; an outlet port configured to receive a permeate stream having a higher concentration of hydrogen gas and / or a lower concentration of other gases relative to the mixed gas stream; a by-product port configured to receive a by-product stream comprising at least a majority of the other gas; and at least one foil microscreen assembly disposed between and secured to the first end frame and the second end frame, at least one hydrogen-selective membrane having a feed side and a permeate side, wherein at least a portion of the permeate stream is formed from a portion of the mixed gas stream passing from the feed side to the permeate side, and a remaining portion of the mixed gas stream remaining on the feed side forms at least a portion of the by-product stream; a foil microscreen assembly including at least one microscreen structure having generally opposed faces configured to support the permeate side and a plurality of flow channels extending between the faces, the at least one hydrogen-selective membrane being metallurgically bonded to the at least one microscreen structure; a plurality of frames disposed between the first and second end frames and the at least one foil microscreen assembly and secured to the first and second end frames, the plurality of frames including at least one transmissive frame disposed between the at least one foil microscreen assembly and the second end frame, the at least one transmissive frame being: A surrounding shell; an outlet conduit formed in the surrounding shell and configured to receive at least a portion of the permeate stream from the at least one hydrogen-selective membrane; an open area surrounded by the surrounding shell; at least one membrane support structure spanning at least a majority of said open area and configured to support said at least one foil microscreen assembly, said membrane support structure being non-perforated.

9. 9. The hydrogen purification apparatus of claim 8, wherein the at least one membrane support structure comprises a single membrane support plate having a first surface and a second surface opposite the first surface.

10. 10. The hydrogen purification apparatus of claim 9, wherein the first surface and the second surface have a plurality of micro-grooves configured to provide a flow path for at least a portion of the permeate stream.

11. The hydrogen purification apparatus according to claim 9 , wherein the first surface and the second surface are free of microgrooves.

12. The hydrogen purification apparatus of claim 8 , wherein the at least one membrane support structure comprises a first membrane support plate and a second membrane support plate stacked within the at least one membrane support structure.

13. 13. The hydrogen purification apparatus of claim 12, wherein each of the first and second membrane support plates is non-perforated and has a first side and a second side opposite the first side, and the first and second membrane support plates are stacked within the at least one membrane support structure such that the second side of the first membrane support plate faces the second side of the second membrane support plate.

14. 14. The hydrogen purification apparatus of claim 13, wherein a first surface of each of the first and second membrane support plates includes a plurality of micro-grooves configured to provide a flow path for at least a portion of the permeate stream.

15. The hydrogen purification apparatus of claim 13 , wherein each of the first membrane support plate and the second membrane support plate is free of micro-grooves.

16. 9. The hydrogen purification apparatus of claim 8, wherein the at least one microscreen structure comprises a non-porous metal sheet having a plurality of openings therethrough that define the plurality of flow channels.

17. The hydrogen purification apparatus of claim 16 , wherein the non-porous metal sheet defines a plane, and each of the plurality of openings has an axis perpendicular to the plane.

18. The hydrogen purifier of claim 16 , wherein one or more of the plurality of openings is oval shaped.

19. The hydrogen purification apparatus of claim 16 , wherein the non-porous metal sheet comprises stainless steel.

20. The hydrogen purification apparatus of claim 16 , wherein the non-porous metal sheet comprises one or more nickel alloys.

21. 1. A foil microscreen assembly for a hydrogen purification apparatus comprising: at least one hydrogen-selective membrane having a feed side and a permeate side, the at least one hydrogen-selective membrane configured to receive a mixed gas stream, form a permeate stream from a portion of the mixed gas stream that passes from the feed side to the permeate side, and form a by-product stream from a remaining portion of the mixed gas stream that remains on the feed side; 1. A foil microscreen assembly comprising: at least one microscreen structure including a non-porous planar sheet having a plurality of openings defining a plurality of flow passages, the non-porous planar sheet including substantially opposed faces configured to support the permeate side, the plurality of flow passages extending between the faces, and a permeate side of the at least one hydrogen-selective membrane metallurgically bonded to the at least one microscreen structure.

22. 22. The foil microscreen assembly of claim 21, wherein the plurality of openings are disposed such that a peripheral portion of the non-porous planar sheet is free of the plurality of openings.

23. 23. The foil microscreen assembly of claim 22, wherein said non-porous planar sheet includes two or more discrete portions having said plurality of apertures disposed therein.

24. 24. The foil microscreen assembly of claim 23, wherein each discrete portion of the two or more discrete portions is separated from an adjacent discrete portion of the two or more discrete portions by at least one boundary portion that is not provided with the plurality of apertures.

25. 24. The foil microscreen assembly of claim 23, wherein the at least one hydrogen-selective membrane comprises two or more hydrogen-selective membranes, each hydrogen-selective membrane of the two or more hydrogen-selective membranes being metallurgically bonded to a respective different one of the two or more discrete portions.

26. 26. The foil microscreen assembly of claim 25, wherein each hydrogen-selective membrane of the two or more hydrogen-selective membranes has a size larger than a corresponding discrete portion such that a peripheral portion of the hydrogen-selective membrane contacts one or more portions of the non-porous planar sheet that are not provided with the plurality of apertures.

27. 22. The foil microscreen assembly of claim 21, wherein said at least one hydrogen-selective membrane is diffusion bonded to said at least one microscreen structure.

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