The application is a divisional application of Chinese patent application with the application date of 2014, 3 months and 3 days, the application number of 201480015413.5 and the name of 'hydrogen production device and hydrogen purification equipment'.
This application claims priority to U.S. patent application serial No. 13/829,766 entitled "hydrogen plant and hydrogen purification apparatus" filed on 3/14/2013. The entire disclosure of the above application is incorporated herein by reference for all purposes.
Detailed Description
Fig. 1 shows an example of a hydrogen production apparatus 20. Unless specifically excluded, the hydrogen-producing assembly may include one or more components of other hydrogen-producing assemblies described in this disclosure. The hydrogen-producing means may comprise any suitable structure configured to produce product hydrogen stream 21. For example, the hydrogen plant may include a feedstock delivery system 22 and a fuel processing apparatus 24. The feedstock delivery system may include any suitable structure configured to selectively deliver at least one feed stream 26 to a fuel processing plant.
In some embodiments, feedstock delivery system 22 may additionally comprise any suitable structure configured to selectively deliver at least one fuel stream 28 to a burner or other heating device of fuel processing plant 24. In some embodiments, feed stream 26 and fuel stream 28 may be the same stream that is delivered to different components of the fuel processing plant. The feedstock delivery system may include any suitable delivery mechanism, such as a positive displacement or other pump or mechanism suitable for propelling a fluid stream. In some embodiments, the feedstock delivery system may be configured to deliver the feed stream 26 and/or the fuel stream 28 without the use of pumps and/or other electrokinetic fluid-delivery mechanisms. Examples of suitable feedstock delivery systems that may be used with hydrogen plant 20 include the feedstock delivery systems described in: U.S. patent nos. 7,470,293 and 7,601,302, and U.S. patent application publication No. 2006/0090397. The entire disclosures of the above-mentioned patents and patent applications are incorporated herein by reference for all purposes.
Feed stream 26 may include at least one hydrogen-producing fluid 30, which may include one or more fluids that may be used as reactants to produce product hydrogen stream 21. For example, the hydrogen-producing fluid may include a carbon-containing feedstock, such as at least one hydrocarbon and/or alcohol. 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-producing fluid 30 may include water, such as when the fuel processing plant generates a product hydrogen stream via steam reforming and/or autothermal reforming. When fuel processing assembly 24 generates a product hydrogen stream via pyrolysis or catalytic partial oxidation, feed stream 26 is free of water.
In some embodiments, feedstock delivery system 22 may be configured to deliver a mixture comprising water and a water-miscible carbon-containing feedstock (such as methanol and/or another water-soluble alcohol). The ratio of water to carbonaceous feedstock in such a fluid stream may vary depending on one or more factors, such as the particular carbonaceous feedstock used, user preferences, the design of the fuel processing apparatus, the mechanism of the fuel processing apparatus used to generate the product hydrogen stream, and the like. For example, the water to carbon ratio may be about 1:1 to 3: 1. Additionally, mixtures of water and methanol can be delivered at a molar ratio of 1:1 or close to 1:1 (37 wt% water, 63 wt% methanol), while hydrocarbons or other alcohols can be delivered at a water-to-carbon molar ratio greater than 1: 1.
When fuel processing plant 24 generates product hydrogen stream 21 via reforming, feed stream 26 can include, for example, from about 25 to about 75 vol% methanol or ethanol (or another suitable water-miscible carbon-containing feedstock) and from about 25 to about 75 vol% water. For feed streams that at least substantially comprise methanol and water, those streams may comprise from about 50 to about 75 vol% methanol and from about 25 to about 50 vol% water. The stream comprising ethanol or other water-miscible alcohol may comprise from about 25 to about 60 vol% alcohol and from about 40 to about 75 vol% water. An example of a feed stream for a hydrogen generator 20 utilizing steam reforming or autothermal reforming comprises 69 vol% methanol and 31 vol% water.
Although the feedstock delivery system 22 is shown configured to deliver a single feed stream 26, the feedstock delivery system may be configured to deliver two or more feed streams 26. Those streams may comprise the same or different feedstocks and may have different compositions, have at least one common component, have no common components, or have the same composition. For example, the first feed stream may include a first component such as a carbonaceous feedstock, and the second feed stream may include a second component such as water. Additionally, although the feedstock delivery system 22 may be configured to deliver a single fuel stream 28 in some embodiments, the feedstock delivery system may be configured to deliver two or more fuel streams. The fuel streams may have different compositions, have at least one common component, have a common component, or have the same composition. In addition, the feed and fuel streams may be discharged from the feedstock delivery system in different phases. For example, one of the streams may be a liquid stream and the other a gas stream. In some embodiments, both streams may be liquid streams, while in other embodiments both streams may be gas streams. Additionally, although hydrogen-producing assembly 20 is shown to include a single feedstock delivery system 22, the hydrogen-producing assembly may include two or more feedstock delivery systems 22.
Fuel processing plant 24 may include a hydrogen-producing region 32 configured to produce an output stream 34 containing hydrogen via any suitable hydrogen-producing mechanism. The output stream may include hydrogen as at least a majority component and may include other gaseous components. The output stream 34 may therefore be referred to as a "mixed gas stream" which contains hydrogen as the major component, but also other gases.
Hydrogen-producing region 32 may include any suitable catalyst-containing bed or region. When the hydrogen-producing mechanism is steam reforming, the hydrogen-producing region may include a suitable steam reforming catalyst 36 to facilitate production of the output stream 34 from the feed stream 26 comprising the carbon-containing feedstock and water. In such embodiments, fuel processing device 24 may be referred to as a "steam reformer," hydrogen-producing region 32 may be referred to as a "reforming region," and output stream 34 may be referred to as a "reformate stream. Other gases that may be present in the reformate stream may include carbon monoxide, carbon dioxide, methane, steam, and/or unreacted carbon-containing feedstock.
When the hydrogen-producing mechanism is autothermal reforming, hydrogen-producing region 32 may include a suitable autothermal reforming catalyst to facilitate production of output stream 34 from feed stream 26 comprising water and a carbon-containing feedstock in the presence of air. Additionally, fuel processing device 24 may include an air delivery device 38 configured to deliver an air stream to the hydrogen-producing region.
In some embodiments, fuel processing plant 24 may include a purification (or separation) zone 40, which may include any suitable structure configured to produce at least one hydrogen-rich stream 42 from output (or mixed gas) stream 34. Hydrogen-rich stream 42 may include a greater concentration of hydrogen than output stream 34 and/or a lower concentration of one or more other gases (or impurities) than are present in the output stream. Product hydrogen stream 21 comprises at least a portion of hydrogen-rich stream 42. Thus, product hydrogen stream 21 and hydrogen-rich stream 42 can be the same stream, and have the same composition and flow rate. Or alternatively, some of the purified hydrogen in hydrogen-rich stream 42 may be stored, such as in a suitable hydrogen storage device, for later use, and/or consumed by a fuel processing device. Purification zone 40 may also be referred to as a "hydrogen purification apparatus" or "hydrogen treatment plant".
In some embodiments, the purification zone 40 may produce at least one byproduct stream 44, which may be free of hydrogen or contain some hydrogen. The byproduct stream may be discharged, sent to a burner unit and/or other combustion source, used as a heating fluid stream, stored for later use and/or otherwise utilized, stored, and/or disposed of. Additionally, purification zone 40 may discharge the byproduct stream as a continuous stream in response to delivery of output stream 34, or may discharge the stream intermittently, such as in a batch manner, or when the byproduct portion of the output stream is at least temporarily retained in the purification zone.
Fuel processing plant 24 may include one or more purification zones configured to produce one or more byproduct streams containing hydrogen in an amount sufficient to be suitable for use as a fuel stream (or feed stream) for a heating device of the fuel processing plant. In some embodiments, the byproduct stream may have sufficient fuel value or hydrogen content to enable the heating device to maintain the hydrogen-producing region at a desired operating temperature or within a selected temperature range. For example, the byproduct stream can include hydrogen, such as 10 to 30 vol% hydrogen, 15 to 25 vol% hydrogen, 20 to 30 vol% hydrogen, at least 10 or 15 vol% hydrogen, at least 20 vol% hydrogen, and the like.
Purification zone 40 can include any suitable structure configured to enrich (and/or increase) the concentration of at least one component of output stream 21. In most applications, the hydrogen-rich stream 42 will have a hydrogen concentration greater than the output stream (or mixed gas stream) 34. The hydrogen-rich stream may also have a lower concentration of one or more non-hydrogen components than present in the output stream 34, and the hydrogen-rich stream has a hydrogen concentration that is higher than, equal to, or lower than the output stream. For example, in conventional fuel cell systems, carbon monoxide may damage the fuel cell stack if present at even a few ppm, while other non-hydrogen components (such as water) that may be present in the output stream 34 will not damage the stack even if present at much higher concentrations. Thus, in such applications, the purification zone may not increase the overall hydrogen concentration, but rather reduce the concentration of one or more non-hydrogen components that are or may be detrimental to the desired use of the product hydrogen stream.
Examples of suitable equipment for purification zone 40 include one or more hydrogen selective membranes 46, chemical carbon monoxide removal devices 48, and/or Pressure Swing Adsorption (PSA) systems 50. Purification zone 40 may include more than one type of purification equipment, and the equipment may have the same or different structures and/or operate by the same or different mechanisms. Fuel processing device 24 may include at least one restrictive orifice and/or other flow restrictors downstream of the purification zone, such as those associated with one or more of the product hydrogen stream, the hydrogen-rich stream, and/or the byproduct stream.
The hydrogen-selective membrane 46 is permeable to hydrogen gas, but substantially, if not completely, impermeable to other components of the output stream 34. Membrane 46 may be formed of any hydrogen permeable material suitable for use in the operating environment and parameters in which purification zone 40 is operated. Examples of suitable materials for membrane 46 include palladium and palladium alloys, particularly thin films of such metals and metal alloys. Palladium alloys have proven particularly effective, especially alloys of palladium with 35 to 45 wt% copper. Palladium-copper alloys containing about 40 wt% copper have proven particularly effective, although other relative concentrations and compositions may also be used. Two particularly effective other alloys are: an alloy of palladium with 2 to 10 wt% gold, especially an alloy of palladium with 5 wt% gold; and alloys of palladium with 3 to 10 wt% indium +0 to 10 wt% ruthenium, especially alloys of palladium with 6 wt% indium +0.5 wt% ruthenium. When palladium and palladium alloys are used, the hydrogen-selective membrane 46 may sometimes be referred to as a "foil".
Chemical carbon monoxide removal means (chemical carbon monoxide removal assemblies)48 are devices that chemically react carbon monoxide and/or other undesirable components of the output stream 34 to form other compositions that are not potentially harmful. Examples of the chemical carbon monoxide removal device include: a water-gas shift reactor configured to produce hydrogen and carbon dioxide from water and carbon monoxide, a partial oxidation reactor configured to convert carbon monoxide and oxygen (typically from air) to carbon dioxide, and a methanation reactor configured to convert carbon monoxide and hydrogen to methane and water. The fuel processing device 24 may include more than one type and/or number of chemical removal devices 48.
Pressure Swing Adsorption (PSA) is a chemical process for removing gaseous impurities from an output stream 34 based on the following principles: that is, under the appropriate temperature and pressure conditions, certain gases will adsorb more strongly to the adsorbent material than others. Typically, non-hydrogen impurities are adsorbed and removed from the output stream 34. The adsorption of impurity gases occurs at higher pressures. As the pressure is reduced, the impurities desorb from the adsorbent material, thereby regenerating the adsorbent material. Typically, PSA is a cyclic process and requires at least two beds operated in series (as opposed to batch). Examples of suitable adsorbent materials that can be used in the adsorbent bed are activated carbon and zeolites. PSA system 50 also provides an example of equipment used in purification zone 40: in this apparatus, the by-products or removed components are not discharged directly from the purification zone as a gas stream simultaneously with the purification of the output stream. Rather, these byproduct components are removed upon regeneration of the adsorbent material or otherwise removed from the purification zone.
In fig. 1, the purification zone 40 is shown within the fuel processing apparatus 24. Or alternatively, the purification zone may be located separately downstream of the fuel processing apparatus, as schematically illustrated in dotted lines in fig. 1. The purification zone 40 may also include portions that are internal or external to the fuel processing apparatus.
The fuel processing device 24 may also include a temperature regulation device in the form of a heating device 52. The heating device may be configured to produce at least one heating fuel stream 28 from at least one heating exhaust stream (or combustion stream) 54, typically combusted in the presence of air. Heated exhaust stream 54 is schematically illustrated in FIG. 1 as heating hydrogen-producing region 32. The heating device 52 may include any suitable structure configured to produce a heated exhaust stream, such as a burner or combustion catalyst in which fuel is combusted with air to produce the heated exhaust stream. The heating device may include an igniter 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 igniters, spark igniters, hot surface igniters, and the like.
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 device, the heating device 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 hot combustion stream 54 that may be used to heat at least the hydrogen-producing region of the fuel processing device. Air may be delivered to the heating device via a variety of mechanisms. For example, air stream 62 may be delivered to the heating device as a separate stream, as shown in FIG. 1. Alternatively, or in addition, the air stream 62 may be delivered to the heating device 52 along with at least one fuel stream 28 for the heating device and/or drawn from the environment in which the heating device is used.
The combustion stream 54 can additionally, or alternatively, be used to heat other portions of the fuel processing apparatus and/or a fuel cell system used with the heating apparatus. In addition, other configurations or types of heating devices 52 may also be used. For example, the heating device 52 may be an electrically powered (electrically powered) heating device, such as a resistive heating element, configured to heat at least the hydrogen-producing region 32 of the fuel processing device 24 by generating heat using at least one heating element. In those embodiments, heating device 52 may not receive and combust a combustible fuel stream to heat the hydrogen-producing region to a suitable hydrogen-producing temperature. An example of a heating device is disclosed in U.S. patent No. 7,632,322, the entire disclosure of which is hereby incorporated by reference for all purposes.
Heating device 52 may be housed (used) with hydrogen-producing and/or separation regions in a common shell or outer shell (using) (as discussed further below). The heating device may be independently disposed from, but in thermal and/or fluid communication with, hydrogen-producing region 32 to provide the desired heating of at least the hydrogen-producing region. The heating means 52 may be located partly or wholly within the common housing and/or at least a part (or all) of the heating means may be located outside the housing. When the heating device is located outside the housing, hot combustion gases from the burner device 60 may be delivered to one or more components within the housing via any suitable heat transfer conduit.
The heating device may also be configured to heat the feedstock delivery system 22, the feedstock supply stream, the hydrogen-producing region 32, the purification (or separation) region 40, or any suitable combination of those systems, streams, and regions. Heating of the feedstock supply stream may include vaporizing a liquid reactant stream or a hydrogen-producing component used to produce hydrogen gas within the hydrogen-producing region. In this embodiment, the fuel processing device 24 may be described as including an evaporation zone 64. The heating device may additionally be configured to heat other components of the hydrogen plant. For example, the heated exhaust stream may be configured to heat a pressure vessel and/or other pressure tank containing a heated fuel and/or hydrogen-producing fluid that forms at least a portion of the feed stream 26 and the fuel stream 28.
Heating device 52 may achieve and/or maintain any suitable temperature in hydrogen-producing region 32. Steam reformers typically operate at temperatures in the range of 200 ℃ to 900 ℃. However, temperatures outside this range are also within the scope of the present disclosure. When the carbon-containing feedstock is methanol, the steam reforming reaction will typically be operated at a temperature in the range of about 200-500 ℃. Examples of such range subsets include 350-. When the carbon-containing feedstock is a hydrocarbon, ethanol, or other alcohol, a temperature range of about 400-. Examples of such ranges include 750-. The hydrogen-producing region 32 may include two or more zones or portions, each of which may operate at the same or different temperatures. For example, when the hydrogen-producing fluid includes hydrocarbons, the hydrogen-producing region 32 may include two different hydrogen-producing portions or regions, one of which operates at a lower temperature than the other to provide the pre-reforming region. In those embodiments, the fuel processing apparatus may also be referred to as including two or more hydrogen-producing regions.
Fuel stream 28 may comprise any combustible liquid and/or gas suitable for consumption by heating device 52 to provide the desired heat output. Some of the fuel stream is gaseous at the time of delivery and combustion by heating device 52, while others may be delivered to the heating device as a liquid stream. Examples of suitable heating fuels for fuel stream 28 include carbonaceous feedstocks such as methanol, methane, ethane, ethanol, ethylene, propane, propylene, butane, and the like. Other examples include low molecular weight condensable fuels (condensable 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 production apparatus 20 that include a cooling device rather than a temperature adjustment device in the form of a heating device, such as may be used when utilizing an exothermic hydrogen generation process (e.g., partial oxidation) rather than an endothermic process (such as steam reforming), the feedstock delivery system may be configured to deliver a fuel or coolant stream to the apparatus. Any suitable fuel or coolant fluid may be used.
Fuel processing assembly 24 may additionally include a housing or casing 66 in which at least hydrogen-producing region 32 is housed, as shown in fig. 1. In some embodiments, the evaporation zone 64 and/or the purification zone 40 can additionally be contained in a housing. The housing 66 may enable components of a steam reformer or other fuel processing mechanism to be moved as a unit. The housing may also protect components of the fuel processing apparatus from damage by providing a protective enclosure (enclosure) and/or may reduce the heating requirements of the fuel processing apparatus as the components may be heated as a unit. The housing 66 may include insulation 68, such as solid insulation, blanket insulation, and/or an air-filled chamber. The insulation material may be inside the housing and/or outside the housing. When the insulation is external to the housing, the fuel processing device 24 may also include an outer cover (outer cover) or jacket 70 external to the insulation, as schematically illustrated in FIG. 1. The fuel processing device may include a different housing that includes other components of the fuel processing device, such as the feedstock delivery system 22 and/or other components.
One or more components of fuel processing device 24 may extend outside of the housing or be located outside of the housing. For example, the purification zone 40 may be located outside the housing 66, such as being separate from the housing but in fluid communication by a suitable fluid transfer conduit. As another example, a portion of hydrogen-producing region 32 (such as a portion of one or more reforming catalyst beds) may extend outside of the shell, such as is schematically indicated in fig. 1 in dashed lines to represent another shell construction. Examples of suitable hydrogen generation devices and components thereof are disclosed in U.S. Pat. Nos. 5,861,137, 5,997,594, and 6,221,117, the entire disclosures of which are incorporated herein by reference for all purposes.
Another example of a hydrogen-producing assembly 20 is shown in fig. 2 and is generally indicated at 72. Unless specifically excluded, hydrogen-producing assembly 72 may include one or more components of hydrogen-producing assembly 20. Hydrogen-generating apparatus 72 may include a feedstock delivery system 74, an evaporation zone 76, a hydrogen-producing zone 78, and a heating apparatus 80, as shown in fig. 2. In some embodiments, hydrogen production assembly 20 may also include a purification zone 82.
The feedstock delivery system may include any suitable structure configured to deliver one or more feed and/or fuel streams to one or more other components of the hydrogen-generating device. For example, the feedstock delivery system may include a feedstock tank (or vessel) 84 and a pump 86. The feedstock tank may contain any suitable hydrogen-producing fluid 88, such as water and a carbon-containing feedstock (e.g., a methanol/water mixture). Pump 86 may have any suitable structure configured to deliver a hydrogen-producing fluid, which may be in the form of at least one feed stream 90 comprising a liquid (which includes water and a carbon-containing feedstock), to vaporization region 76 and/or hydrogen-producing region 78.
The vaporization zone 76 can 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, the vaporization zone 76 can include an evaporator 92 configured to at least partially convert the liquid-containing feed stream 90 into one or more vapor feed streams 94. In some embodiments, the vapor feed stream may comprise a liquid. An example of a suitable evaporator is a coil evaporator, such as a stainless steel coil.
Hydrogen-producing region 78 may include any suitable structure configured to receive one of a plurality of feed streams from a vaporization region, such as steam feed stream 94, to produce one or more output streams 96 containing hydrogen as a major component and other gases. The hydrogen-producing region may produce the output stream via any suitable mechanism. For example, hydrogen-producing region 78 may be generated via a steam reforming reaction. In this example, hydrogen-producing region 78 may include a steam reforming region 97 having a reforming catalyst 98 configured to facilitate and/or promote the steam reforming reaction. When hydrogen-producing region 78 generates output stream 96 via a steam reforming reaction, hydrogen-producing assembly 72 may be referred to as a "steam reforming hydrogen-producing assembly," and output stream 96 may be referred to as a "reformate stream.
Heating device 80 may include any suitable structure configured to produce at least one heated exhaust stream 99 for heating one or more other components of hydrogen-producing device 72. For example, the heating device can heat the vaporization zone to any suitable temperature, such as at least a minimum vaporization temperature or a temperature at which at least a portion of the feed stream comprising liquid is vaporized to form a vapor feed stream. Additionally, or alternatively, heating device 80 may heat the hydrogen-producing region to any suitable temperature, such as at least a minimum hydrogen-producing temperature or a temperature at which at least a portion of the steam feed stream reacts to produce hydrogen to form an output stream. One or more components of the heating device, such as the evaporation zone and/or the hydrogen-producing zone, of the hydrogen-producing device are in thermal communication.
The heating device may include a burner device 100, at least one blower 102, and an igniter device 104, as shown in fig. 2. The burner apparatus may include any suitable structure configured to receive at least one air stream 106 and at least one fuel stream 108 and combust the at least one fuel stream in a combustion zone 110 to produce a heated exhaust stream 99. The fuel stream may be provided by the feedstock delivery system 74 and/or the purification zone 82. The combustion zone may be contained within the housing of the hydrogen-producing apparatus. Blower 102 may include any suitable structure configured to generate air stream 106. Igniter device 104 may include any suitable structure configured to ignite fuel stream 108.
Purification zone 82 may include any suitable structure configured to produce at least one hydrogen-rich stream 112, which hydrogen-rich stream 112 may include a higher concentration of hydrogen than output stream 96 and/or a lower concentration of one or more other gases (or impurities) than is present in the output stream. The purification zone may produce at least one byproduct stream or fuel stream 108 that may be sent to the burner apparatus 100 and used as a fuel stream for the apparatus, as shown in fig. 2. Purification zone 82 may include a flow restriction orifice 111, a filter arrangement 114, an a-membrane arrangement 116, and a methanation reactor arrangement 118. A filter device (such as one or more hot gas filters) can be configured to remove impurities from the output stream 96 prior to hydrogen purification of the membrane device.
Membrane device 116 may include any suitable structure configured to receive an output or mixed gas stream 96 comprising hydrogen and other gases and generate a permeate or hydrogen-rich stream 112 comprising a higher concentration of hydrogen and/or a lower concentration of other gases than the mixed gas stream. The membrane device 116 may incorporate hydrogen permeability (or hydrogen selectivity) in the form of a flat or tubular membrane, and more than one hydrogen permeable membrane may be incorporated into the membrane device 116. The permeate stream may be used in any suitable application, such as in one or more fuel cells. In some embodiments, the membrane device may generate a byproduct or fuel stream 108 that includes at least a majority of the other gases. Methanation reactor assembly 118 may include any suitable structure configured to convert carbon monoxide and hydrogen to methane and water. Although the purification zone 82 is shown to include a flow restriction orifice 111, a filter arrangement 114, a membrane arrangement 116, and a methanation reactor arrangement 118, the purification zone may have less than all of those arrangements and/or may alternatively, or additionally, include one or more other components configured to purify the output stream 96. For example, purification zone 82 may include only membrane device 116.
In some embodiments, hydrogen-producing assembly 72 may include a housing or enclosure 120, which may at least partially contain one or more other components of the assembly. For example, housing 120 may at least partially contain evaporation zone 76, hydrogen-producing zone 78, heating device 80, and/or purification zone 82, as shown in FIG. 2. The housing 120 may include one or more exhaust ports 122 configured to exhaust at least one combustion exhaust stream 124 generated by the heating device 80.
In some embodiments, hydrogen-producing assembly 72 may include a control system 126, which may include any suitable structure configured to control the operation of hydrogen-producing assembly 72. For example, the control device 126 may include a control device 128, at least one valve 130, at least one pressure relief valve 132, and one or more temperature measurement devices 134. Control apparatus 128 may detect the temperature in the hydrogen-producing region and/or the purification region via a temperature measurement device 134, which temperature measurement device 134 may include one or more thermocouples and/or other suitable devices. Based on the sensed temperature, an operator of the control apparatus and/or control system may regulate delivery of feed stream 90 to vaporization region 76 and/or hydrogen-producing region 78 via 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 (excess pressure) in the system can be relieved.
In some embodiments, hydrogen-producing 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-producing assembly to another portion. For example, heat exchange device 136 can transfer heat from hydrogen-rich stream 112 to feed stream 90 to raise the temperature of the feed stream prior to entering vaporization zone 76, as well as cool hydrogen-rich stream 112.
An example of the purification zone 40 (or hydrogen purification device) of the hydrogen plant 20 of fig. 1 is generally shown at 144 in fig. 3. Unless specifically excluded, the hydrogen purification apparatus may include one or more components of other purification zones described in this disclosure. The hydrogen purification apparatus 40 may include a hydrogen-separation zone 146 and an enclosure 148. The outer cover may define an interior volume (intervalgum) 150 having an inner periphery 152. The enclosure 148 may include at least a first portion 154 and a second portion 156 that are joined together to form a body 149 in the form of a sealed pressure vessel that may include defined input and output ports. Those ports may define fluid paths for delivering gases and other fluids into and out of the interior volume of the housing.
Any suitable fastening may be used for first and second portions 154 and 156
The mechanisms or mechanisms 158 are integrated together. Examples of suitable securing mechanisms include welding and/or bolts. Examples of seals that may be used to provide a fluid-tight interface between the first and second portions may include gaskets and/or welds. Additionally, or alternatively, first and second portions 154 and 156 may be fastened together to apply at least a predetermined amount of pressure (compression) to various components defining the hydrogen-separation region within the enclosure and/or other components that may be added to the hydrogen-producing device. The applied pressure ensures that the various components are held in place within the housing. Additionally, or alternatively, pressure applied to the plurality of components and/or other components defining the hydrogen-separation zone within the housing may provide a fluid-tight interface between the plurality of components defining the hydrogen-separation zone, between the plurality of other components, and/or between the plurality of components defining the hydrogen-separation zone and other components.
Housing 148 may include a mixed gas zone 160 and a permeate zone 162, as shown in FIG. 3. The mixed gas zone and the permeation zone may be separated by a hydrogen-separation zone 146. At least one input port 164 can be provided through which a fluid stream 166 can be delivered into the housing. Fluid stream 166 can be a mixed gas stream 168 comprising hydrogen 170 and other gases delivered to mixed gas zone 160. Hydrogen may be the major component of the mixed gas stream. The hydrogen-separation zone 146 may extend between the mixed gas zone 160 and the permeation zone 162, so the gases in the mixed gas zone must pass through the hydrogen-separation zone to enter the permeation zone. The gas may, for example, need to pass through at least one hydrogen-selective membrane as discussed further below. The permeate region and the mixed gas region may have any relative dimensions suitable for use in an enclosure.
Housing 148 can also include at least one product outlet 174 through which a permeate stream 176 can be received and removed from the permeable zone 162. The permeate stream may comprise at least one of a higher concentration of hydrogen and a lower concentration of other gases than the mixed gas stream. In some embodiments, the permeate stream 176 may initially include at least a carrier or sweep gas (sweep) gaseous component, such as may be delivered as a sweep gas stream 178 through a sweep gas port 180 in fluid communication with the permeate zone. The housing may also include at least one byproduct output 182 through which a byproduct stream 184 containing at least one of a majority of the other gas 172 and a lower concentration of hydrogen 170 (relative to the mixed gas stream) may be removed from the mixed gas zone.
The hydrogen-separation zone 146 may include at least one hydrogen-selective membrane 186 having a first or mixed gas surface 188 oriented to contact the mixed gas stream 168, and a second or permeate surface 190 generally opposite the surface 100. The mixed gas stream 168 may be delivered to the mixed gas zone of the housing such that it is in contact with the mixed gas surface of the one or more hydrogen-selective membranes. The permeate stream 176 can be formed from at least a portion of the mixed gas stream passing through the hydrogen-separation zone into the permeate zone 162. Byproduct stream 184 can be formed from at least a portion of the mixed gas stream that does not pass through the hydrogen-separation zone. In some embodiments, byproduct stream 184 may comprise a portion of the hydrogen present in the mixed gas stream. The hydrogen-separation zone may also be configured to capture or otherwise retain at least a portion of other gases that are subsequently removed as a byproduct stream when the separation zone is replaced, regenerated, or otherwise recharged (recorged).
In fig. 3, streams 166, 176, 178, and/or 184 may include more than one actual stream flowing into or out of hydrogen purification apparatus 144. For example, the hydrogen purification apparatus may receive a plurality of mixed gas streams 168, a single mixed gas stream 168 that is split into two or more streams prior to contact with the hydrogen-separation zone 146, a single stream that is delivered into the inner volume 150, and the like. Accordingly, the housing 148 may include more than one input port 164, product output port 174, off-gas port 180, and/or byproduct output port 182.
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 is operated. Examples of hydrogen purification devices are disclosed in U.S. Pat. nos. 5,997,594 and 6,537,352, 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 a palladium alloy. Examples of palladium alloys include palladium alloyed with copper, silver and/or gold. Examples of various membranes, membrane constructions, and methods of making membranes and membrane constructions are disclosed in U.S. Pat. nos. 6,152,995, 6,221,117, 6,319,306, and 6,537,352, the entire disclosures of which are incorporated herein by reference for all purposes.
In some embodiments, a plurality of spaced-apart (spaced-apart) hydrogen-selective membranes 186 may be used in the hydrogen-separation zone to form at least a portion of the hydrogen-separation device 192. When present, the plurality of membranes may collectively define one or more membrane devices 194. In such embodiments, the hydrogen-separation device may generally extend from the first portion 154 to the second portion 156. Thus, the first and second portions can effectively compact (compress) the hydrogen-separating device. In some embodiments, enclosure 148 may additionally, or alternatively, include end plates (or end frames) connected to both sides (sides) of the body portion (body portion). In such embodiments, the end plates may effectively compress the hydrogen-separation device (and other components that may be housed within the enclosure) between a pair of opposing end plates.
Hydrogen purification using one or more hydrogen-selective membranes is typically a pressure-driven separation process in which a mixed gas stream is delivered in contact with the mixed gas surface of the membrane at a pressure higher than the gas in the permeation zone of the hydrogen-separation zone. In some embodiments, when a hydrogen-separation zone is used to separate the mixed gas stream into a permeate stream and a byproduct stream, the hydrogen-separation zone 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 deg.C, at least 325 deg.C, at least 350 deg.C, temperatures in the range of 275-500 deg.C, temperatures in the range of 275-375 deg.C, temperatures in the range of 300-450 deg.C, temperatures in the range of 350-450 deg.C, and the like.
An example of a hydrogen purification apparatus 144 is generally shown at 196 in fig. 4. Unless specifically excluded, hydrogen purification apparatus 196 can include one or more components of other hydrogen purification apparatuses and/or purification zones described in the present disclosure. Hydrogen purification apparatus 196 may include a housing or enclosure 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 configured to be fastened and/or compressed together to define a sealed pressure vessel having an interior compartment 204 in which the hydrogen-separation zone is supported within the interior compartment 204. Similar to the hydrogen purification apparatus 144, the first and second end plates may include input, output, off-gas and byproduct ports (not shown).
Hydrogen purification apparatus 196 may also include at least one hydrogen selective membrane 206 and at least one microsieve structure 208. The hydrogen-selective membrane may be configured to receive at least a portion of the mixed gas stream from the input port and separate the mixed gas stream into at least a portion of a permeate stream and at least a portion of a byproduct 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 passing from the feed side to the permeate side, while the remaining portion of the mixed gas stream remaining on the feed side forms at least a portion of the byproduct stream. In some embodiments, the hydrogen-selective membrane 206 may be secured to at least one membrane frame (not shown), which may then be secured to the first and second end frames.
The microsieve structure 208 may include any suitable structure configured to support at least one hydrogen-selective membrane. For example, the microsieve structure may include generally opposing surfaces 214 and 216 configured to provide support to the permeate side 212 and a plurality of fluid passageways 218 extending between the opposing surfaces and allowing a permeate stream to flow through the microsieve structure, as shown in fig. 4. Microsieve structure 208 may comprise any suitable material. For example, the microsieve structure may comprise stainless steel, such as stainless steel comprising an aluminum oxide layer configured to prevent diffusion between the stainless steel and the at least one hydrogen-selective membrane.
In some embodiments, the microsieve structure may include stainless steel 303 (aluminum modified), 17-7PH, 14-8PH, and/or 15-7 PH. In some embodiments, the stainless steel may include about 0.6 to about 1.5 wt% aluminum. The microsieve structure 208 can be sized such that it is contained (such as completely contained) in the open area of the permeate frame and/or supported by the membrane support structure in the open area, as shown in fig. 5. In other words, the microsieve structure may be sized such that it does not contact the outer perimeter shell of the permeable frame when the microsieve structure and permeable frame are fastened or compressed to the first and second end frames.
Or alternatively, the microsieve structure may be supported and/or secured by a non-porous peripheral wall portion or frame (not shown), such as by a peripheral shell of a permeable frame. When the microsieve structure is fastened to the non-porous peripheral wall portion, the microsieve structure may be referred to as a "porous central region portion". Examples of other microsieve structures are disclosed in U.S. patent application publication No. 2010/0064887, the entire disclosure of which is hereby incorporated by reference for all purposes.
The hydrogen purification apparatus 196 may also include a plurality of plates or frames 224 not known to be between or secured to the first and/or second end frames. The frame may comprise any suitable structure and/or may be any suitable shape, such as square, rectangular or circular. For example, the frame 224 may include a peripheral housing 226 and at least a first support member 228, as shown in fig. 4. The peripheral housing may define an open area 230 and a frame plane 232. In addition, the peripheral housing 226 may include first and second opposing sides (opposing sides)234 and 236, and third and fourth opposing sides 238 and 240, as shown in fig. 4.
First support member 228 may include any suitable structure configured to support first portion 242 of hydrogen-selective membrane 206, as shown in fig. 4. For example, first support members of the plurality of frames can be coplanar with one another (or with other first support members of other frames of the plurality of frames) in the first support surface 244 to support the first portion 242 of the hydrogen-selective membrane, as shown in fig. 4. In other words, the first support member of each frame of the plurality of frames may be a mirror image of the first support members of the other frames of the plurality of frames. The first support member may have any suitable orientation relative to the frame plane 232. For example, the first support plane 244 may be perpendicular to the frame plane, as shown in fig. 4. Or alternatively, the first membrane support plane may intersect but not be perpendicular to the frame plane 232.
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 hydrogen-selective membrane 206, as shown in fig. 4. For example, 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) in a second support plane 254 to support the second portion 250 of the hydrogen-selective membrane. Additionally, third support members of the plurality of frames may be coplanar with each other or (or with other third support members of the plurality of frames) in a third support plane 256 to support the third portion 252 of the hydrogen-selective membrane. In other words, the second support member of each of the plurality of frames may be a mirror image of the second support members of the other of the plurality of frames, and the third support member of each of the plurality of frames may be a mirror image of the third support members of the other of the plurality of frames. The second and/or third support planes may have any suitable orientation relative to the frame plane 232. For example, the second support plane 254 and/or the third support plane 256 may be perpendicular to the frame plane, as shown in fig. 4. Or alternatively, the second and/or third support planes may intersect but not be perpendicular to the frame plane 232.
Second support member 246 and/or third support member 248 may have any suitable orientation relative to first support member 228. For example, the first support member 228 may extend into the open area 230 from a third side 238 of the peripheral housing 226; the second support member 246 may extend into the open area from a fourth side of the outer peripheral shell (which is opposite the third side); and the third support member 248 may extend into the open area from a third side. Or alternatively, the first, second and/or third support members may extend into the open area from the same side, such as from the first, second, third or fourth side of the peripheral housing. In some embodiments, the first, second and/or third support members may extend into the open area from a first side and/or a second side (which is opposite the first side) of the peripheral housing.
The first, second and/or third support members may, for example, be in the form of one or more projections or fingers 258 connected to and/or formed with the peripheral housing. The protrusions may extend from the peripheral housing in any suitable direction. The protrusion may be the full thickness of the peripheral shell or may be less than the full thickness of the shell. The protrusions of each frame of the frame 224 may compress the hydrogen-selective membrane to lock the membrane in place and reduce the effect of hydrogen-selective membrane expansion due to hydrogen dissolution. In other words, the protrusions of the frame 224 may support the hydrogen-selective membrane by stacked extensions(s) of the end frames within the first and/or second membrane support planes. In some embodiments, the protrusions 258 may include one or more receptacles or holes (not shown) configured to receive at least one fastener (not shown) to secure the frame 224 to the first and/or second end frames.
The frame 224 may include at least one feed frame 260, at least one permeate frame 262, and a plurality of pads or pad frames 264, as shown in fig. 4. The feed frame 260 may be disposed between one of the first and second end frames and the at least one hydrogen-selective membrane 206, or between two hydrogen-selective membranes 206. The feeder frame may include a feeder frame outer perimeter housing 266, a feeder frame input conduit 268, a feeder frame output conduit 270, a feeder frame open area 272, at least a first feeder frame support member 274, as shown in fig. 4. In some embodiments, the feeder frame may include a second feeder frame support member 276 and/or a third feeder frame support member 278.
The outer peripheral housing 266 of the feeder frame may comprise any suitable structure. For example, the peripheral housing of the feed frame can include a first section (first section) or first peripheral housing 280 and a second section or second peripheral housing 282, as shown in fig. 6. Note that the components of fig. 6 have been exaggerated for illustrative purposes and do not reflect the relative sizes of those components. The first and second segments may be first and second halves (holves) of the peripheral housing, or may be any suitable portion of the peripheral housing. Additionally, the first and/or second segments may include channels or grooves (not shown) in any suitable relationship with one another, such as offset from one another. The first segment 280 and the second segment 282 may be joined via any suitable method to form a hermetic seal between those segments. For example, a feed frame liner 284 may be used between those sections. Or alternatively, the first and second segments may be brazed together or the first and second segments may be joined using a ply-bonding metal, as described in U.S. patent application publication No. 2013/0011301. The entire disclosure of which is incorporated herein by reference for all purposes.
Additionally, the outer perimeter housing 266 of the feed frame may include any suitable specifications (dimensions) configured to support the other components of the hydrogen purification apparatus 196. For example, the peripheral shell of the feed frame may be sized such that it supports the peripheral shell of the permeate frame 262 and the membrane support structures 286 of those frames along a plurality of feed frame support planes 288. For example, the width of the peripheral housing 266 may be greater than the width 292 of the peripheral housing of the permeate frame 262 such that at least a portion 294 of the peripheral housing supports a portion 296 of the membrane support structure 286, as shown in fig. 6. In other words, the peripheral housing of the feed frame may lock the membrane support structure in place and act as a stop (stop) for the support structure. The feeder frame support plane may have any suitable orientation relative to the feeder frame plane 300. For example, the feeder frame support plane may be perpendicular to the feeder frame plane, as shown in fig. 6. Or alternatively, the feeder frame support planes may intersect but not be perpendicular to the feeder frame plane 300.
The feed frame input conduit can be formed on a peripheral shell of the feed frame and/or configured to receive at least a portion of the mixed gas stream from the input port. The feed frame output conduit 270 can be formed on the outer perimeter shell of the feed frame and/or configured to receive the remainder of the mixed gas stream remaining on the feed side 210 of the hydrogen-selective membrane 206. The feed frame open area 272 may be disposed between the feed frame input and output conduits. The outer perimeter housing 266 of the feeder frame may include a plurality of grooves or channels (not shown) that fluidly communicate the input and output conduits with the open area of the feeder frame. The channels may be formed on the outer perimeter shell via any suitable method and/or may have any suitable orientation, such as an angled orientation that may cause mixing in the feed frame open area 260.
The first, second and/or third feed frame support members may comprise any suitable structure configured to support the first, second and/or third portions of the at least one hydrogen-selective membrane and/or may mirror the first, second and/or third support members of the other frame. Additionally, the first, second, and/or third feed frame support members may comprise any suitable structure configured to change the direction of flow of at least a portion of the mixed gas stream as it flows through the open area of the feed frame between the input and output conduits. The first and/or second feeder frame support members may also be configured to promote turbulence or mixing within the open area of the feeder frame. For example, the flow of at least a portion of the mixed gas stream flowing through the open area of the feed frame between the input and output conduits may be moved in at least a first direction (not shown) without the first and/or second feed frame support members. The first and/or second feed frame membrane support structures can be configured to change 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) different from the first direction.
The first, second and/or third feeder frame support members may, for example, be in the form of at least one feeder frame projection or finger 302 connected to and/or formed with the peripheral casing of the feeder frame. The feeder frame projection may extend from the peripheral housing in any direction. For example, the feed frame protrusions can extend from the peripheral shell of the feed frame in a direction that is generally perpendicular (and/or generally parallel) to the direction of flow of at least a portion of the mixed gas stream from the input conduit to the open area of the feed frame. For example, if the flow of the mixed gas stream from the input conduit to the open area of the feed frame is generally horizontal, the feed frame protrusions may extend from the peripheral shell of the feed frame in a substantially vertical and/or horizontal direction.
The permeate frame 262 may be configured such that at least one hydrogen-selective membrane is disposed between one of the first and second end frames and the permeate frame or between two hydrogen-selective membranes. The permeate frame may include a permeate frame outer perimeter shell 304, a permeate frame output conduit 306, a permeate frame open area 308, and a membrane support structure 286, as shown in fig. 5.
The outer perimeter shell of the infiltration frame may comprise any suitable structure. For example, the outer perimeter shell of the infiltration frame may include a first segment or first outer perimeter shell 310 and a second segment or second outer perimeter shell 312, as shown in fig. 6. The first and second segments may be first and second halves of the outer shell, or may be any suitable portion of the outer shell. Additionally, the first and/or second segments may include channels or grooves (not shown) in any suitable relationship with one another, such as offset from one another. The first section 310 and the second section 312 may be joined via any suitable method to form a gas-tight seal between those sections. For example, a permeable frame liner 314 may be used between those segments. The permeate frame cushion can be configured such that when the permeate frame 262 is secured to the first and second end frames, a thickness 316 of the outer perimeter shell of the permeate frame matches or substantially matches (is equal to or substantially equal to) a thickness 318 of the membrane support structure, as shown in fig. 6 and discussed further below.
Or alternatively, the first and second segments may be brazed together, or a layer-bonding metal may be used to join the first and second segments, as described in U.S. patent application publication No. 2013/0011301. The entire disclosure of which is incorporated herein by reference for all purposes.
In some embodiments, the outer perimeter shell 304 of the infiltration frame 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. 7. Those segments may be the first, second and third of the peripheral casing (thirds), or may be any suitable portion of the peripheral casing. Additionally, the first, second, and/or third sections may include channels or grooves (not shown) in any suitable relationship with one another, such as offset from one another. Note that the components of fig. 7 have been enlarged for illustrative purposes and do not reflect the relative sizes of those components.
First section 320, second section 322, and third section 324 may be joined via any suitable method to form a hermetic seal between those sections. For example, a permeable frame gasket 326 may be used between those segments. The permeate frame cushion can be configured such that when the permeate frame 262 is secured to the first and second end frames, a thickness 316 of the outer perimeter shell of the permeate frame matches or substantially matches (is equal or substantially equal to) a thickness 318 of the membrane support structure, as shown in fig. 6. Or alternatively, the first, second, and/or third sections may be brazed together or the first, second, and/or third sections may be joined using a layer bonding metal, as described in U.S. patent application publication No. 2013/0011301. The entire disclosure of which is incorporated herein by reference for all purposes.
The output conduit 306 may be formed on the outer perimeter housing 282 of the permeation frame and/or configured to receive a permeate stream from the membrane support structure 286, the permeation frame open area 308, and/or the hydrogen-selective membrane. The peripheral housing 282 may include a plurality of grooves or channels (not shown) that fluidly communicate the outlet conduit with the permeate frame open area and/or the membrane support structure. The channels may be formed on the outer perimeter shell 282 via any suitable method and/or may have any suitable orientation, such as an angled orientation.
Membrane support structure 286 may include any suitable structure configured to support at least one hydrogen-selective membrane, such as first, second, third, and/or other portions of a hydrogen-selective membrane. In some embodiments, the membrane support structure may include first, second, and/or third support members (not shown), similar to one or more other frames. Or alternatively, the membrane support structure 288 may include a plurality of membrane support plates 328, as shown in fig. 6. The membrane support plate may span any suitable portion of the open area, such as at least a majority of the open area. Additionally, the membrane support plate may be solid, flat or planar, free of perforations or holes (or free of perforations or holes), free of ridges and/or protrusions (or free of ridges and/or protrusions), and/or may be incompressible (or substantially incompressible). Furthermore, the membrane support plates may not be connected to the outer perimeter shell of the permeate frame (or without connectors). In other words, when the feed frame is fastened to the first and second end plates, only the feed frame may lock the membrane support structure in place in the open area of the peripheral casing of the permeate frame. Additionally, the membrane support plate may be made of any suitable material, such as stainless steel.
The membrane support plate 328 may include a first face (or surface) 330 and a second opposing face (or opposing surface) 332, as shown in fig. 6. The membrane support plate may include a plurality of microchannels 334, as shown in FIG. 8, which may include any suitable structure that provides one or more paths for the flow of permeate. When the membrane support plates 328 include surface microchannels, those plates may be referred to as "surface-grooved plates". The microgrooves may have any suitable orientation, such as parallel to each other. In addition, the micro-grooves 334 may extend from a first edge 336 to a second opposing edge 338 of the membrane support plate, as shown in fig. 8 (or from a third edge to a fourth opposing edge). Or alternatively, one or more of the microgrooves can extend from the first edge to before the second edge, from the second edge to before the first edge, between but not including the first and second edges, and so forth. Further, the microgrooves 334 may be on only the first face, only the second face, or both the first and second faces. In addition, the micro-grooves may be contained throughout the length or width of the membrane support plate (as shown in fig. 8), or may be on any portion of the length or width, such as 25%, 50%, or 75% of the length or width.
The micro-grooves 334 may have any suitable dimensions. For example, the microgrooves may have a width of 0.005 to 0.020 inches (or preferably 0.010 to 0.012 inches) and a depth of 0.003 to 0.020 inches (or preferably 0.008 to 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 micro-grooves may be fabricated by any suitable method, such as chemical etching, machining, and/or the like.
In some embodiments, membrane support structure 286 may include a first membrane support plate 340 and a second membrane support plate 342, as shown in fig. 6. The first membrane support plate can include a first face 344 and a second opposing face 346. The second membrane support plate 342 can include a first face 348 and a second opposing face 349. The first face of the first and/or second membrane support plates may include micro-grooves 334. In addition, the second faces of the first and second membrane support plates may face each other. In other words, the first and second membrane support plates may be stacked on the membrane support structure such that the second face of the first membrane support plate faces the second face of the second membrane support plate, and/or vice versa. In some embodiments, the second face of the first membrane support plate can contact the second face of the second membrane support plate.
In some embodiments, the membrane support structure may include a third membrane support plate 350, which may be unknown between the first and second membrane support plates, as shown in fig. 9. Note that the components of fig. 9 have been enlarged for explanatory purposes and do not reflect the relative sizes of those components. The membrane support structure may comprise first, second and third membrane support plates stacked such that the third membrane support plate contacts the second face of the first and/or second membrane support plate. When a third film support panel is disposed between the first and second film support panels, the third film support panel may sometimes be referred to as a "center panel". The third membrane support plate may be free of micro-grooves on one or both sides thereof. The first, second and third membrane support plates may have any suitable dimensions. For example, the first and second film support plates may be 0.060 inches and the third film support plate may be 0.105 inches.
As discussed above, the permeate frame cushion 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 fastened and/or compressed against the first and second end frames. The thickness of those liners prior to compression is greater than the thickness of the membrane support structure. When an elastic graphite gasket is used for a permeable frame gasket having compression limits of 15 to 50%, then the thickness of the permeable frame gasket prior to compaction may result in a desired final thickness that falls within those compression limits. When the infiltration frame includes such a liner, the infiltration frame may sometimes be referred to as a "self-regulating infiltration frame". When the self-regulating permeate frame is compressed during assembly by the feed frame (e.g., at a pressure of 1000 to 2000 psi) to form a gas-tight seal between the feed frame and the hydrogen-selective membrane, the pressure of the feed frame against the permeate frame can be resisted when the feed frame contacts the hydrogen-selective membrane, the microsieve structure, and the membrane support structure (which together can form a substantially incompressible assembly or stack of assemblies).
As an example, if the membrane support structure has a thickness of 0.257 inches, it may be desirable for the permeate frame to have a thickness of precisely or about 0.257 inches. When the outer perimeter shell of the infiltration frame includes two sections that are each, for example, 0.120 inches thick, then the infiltration frame liner should be constructed to be 0.017 inches thick after compaction. For example, a permeate frame cushion that is 0.030 inches thick before compression can be compressed within its compression limit to 0.017 inches after compression, which will result in a permeate frame thickness that matches the membrane support structure thickness. Although the membrane support structure 286 is shown as including the membrane support plate 328, the membrane support structure may include a wire mesh and/or a perforated metal sheet (not shown).
The frame 224 may also include a cushion or cushion frame 264, as shown in fig. 4. The cushion frame may include any suitable structure configured to provide a fluid-tight interface between other frames, such as between the first and second end plates 200 and 202 and the feed frame 260Between the feed frame 260 and the hydrogen-selective membrane 206, between the hydrogen-selective membrane (and the microsieve structure) and the permeate frame 262. An example of a gasket suitable for use in the gasket frame 264 is a resilient graphite gasket. Another example of a suitable gasket material is866, sold by Flexitallic LP (De 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 hydrogen purification apparatus 196 is shown to include two hydrogen-selective membranes 206, the apparatus may include any suitable number of those membranes.
Although one or more of the frames 224 are shown as including protrusions extending in only a vertical direction or only a horizontal direction, the frames may additionally, or alternatively, include protrusions extending in a horizontal, vertical, and/or other suitable direction (e.g., diagonal, etc.). Additionally, although one or more of the frames 224 are shown to include three protrusions, the frame may include one, two, four, five, or more protrusions. Further, while one or more of the frames 224 are shown to include projections that are coplanar within the first, second, and/or third support planes, the frame may additionally, or alternatively, include projections that are coplanar within the fourth, fifth, or more support planes.
Other examples of hydrogen-producing apparatus 20 are generally shown at 354 in fig. 10. Unless specifically excluded, hydrogen-producing assembly 354 may include one or more components of one or more other hydrogen-producing assemblies described in this disclosure. The hydrogen-producing assembly may provide or supply hydrogen to one or more hydrogen-consuming devices 356, such as fuel cells, hydrogen furnaces, and the like. Hydrogen production assembly 354 may, for example, include a fuel processing assembly 358 and a product hydrogen management system 360.
Fuel processing device 358 may include any suitable structure configured to generate one or more product hydrogen streams 362 (such as one or more hydrogen streams) from one or more feed streams 364 via one or more suitable mechanisms, such as steam reforming, autothermal reforming, electrolysis, pyrolysis, partial oxidation, plasma reforming, photocatalytic water splitting, sulfur-iodine recycle, and the like. For example, fuel processing device 358 may include one or more hydrogen generator reactors 366, such as a reformer, an electrolyzer, or the like. The feed stream 364 may be delivered to the fuel processing plant from one or more feedstock delivery systems (not shown) via one or more feed conduits 368.
The fuel processing device 358 may be configured to operate in a plurality of modes, such as a run mode and a standby mode. In the operating mode, the fuel processing device may produce or generate a product hydrogen stream from the feed stream. For example, in an operational mode, the feedstock delivery system may deliver a feed stream to a fuel processing plant and/or may perform other operations. Additionally, in the operating mode, the fuel processing device may receive the feed stream, may combust the fuel stream via the heating device, may vaporize the feed stream via the vaporization region, may generate the output stream via the hydrogen-producing region, may generate the product hydrogen stream and the byproduct stream via the purification region, and/or may perform other operations.
In the standby mode, fuel processor 358 is unable to produce a product hydrogen stream from the feed stream. For example, in a standby mode, the feedstock delivery system is unable to deliver a feed stream to the fuel processing plant and/or is unable to perform other operations. Additionally, in the standby mode, the fuel processing device is unable to receive the feed stream, is unable to combust the fuel stream via the heating device, is unable to vaporize the feed stream via the evaporation zone, is unable to generate an output stream via the hydrogen-producing zone, is unable to generate a product hydrogen stream and a byproduct stream via the purification zone, and/or is unable to perform other operations. The standby mode may include when the energy source of the fuel processing device is off or when the fuel processing device is without energy source.
In some embodiments, the plurality of modes may include one or more reduced output modes (reduced output modes). For example, the fuel processor 358 may produce or generate the product hydrogen stream 362 at a first output rate (such as at a maximum output rate or a normal output rate) in the run mode, and may produce or generate the product hydrogen stream at a second, third, fourth, or more rates that are lower than the first rate (such as at a minimum output rate) in the reduced output mode.
The product hydrogen management system 360 may include any suitable structure configured to manage the product hydrogen generated by the fuel processing device 358. Additionally, the product hydrogen management system may include any suitable structure configured to interact with the fuel processing device 358 to maintain any suitable amount of product hydrogen available to the hydrogen-consuming equipment 356. For example, product hydrogen management system 360 may include a product conduit 370, a surge tank 372, a surge tank conduit 374, a sensor device 376, and a control device 378.
Product conduit 370 may be configured to fluidly communicate fuel processing apparatus 358 with a buffer tank 372. Surge tank 372 may be configured to receive product hydrogen stream 362 via product conduit 370 to maintain a predetermined amount or volume of the product hydrogen stream and/or to provide the product hydrogen stream to one or more hydrogen-consuming devices 356. In some embodiments, the buffer tank may be a low pressure buffer tank. The buffer tank may be any suitable size, depending on one or more factors, such as the anticipated or actual hydrogen consumption of the hydrogen-consuming equipment, the cycling characteristics of the hydrogen generator reactor, the fuel processing equipment, and the like.
In some embodiments, buffer tank 372 may be sized to provide hydrogen for a minimum amount of time sufficient for operating the hydrogen-consuming equipment and/or a minimum amount of time for operating the fuel processing plant, e.g., a minimum amount of time for operating the vaporization region, the hydrogen-producing region, and/or the purification region. For example, the surge tank may be sized to allow operation of the fuel processing device for 2, 5, 10, or more minutes. Surge tank conduit 374 may be configured to fluidly communicate surge tank 372 and hydrogen-consuming device 356.
Sensor device 376 may include any suitable structure configured to detect and/or measure one or more suitable operating variables and/or parameters in the surge tank and/or generate one or more signals based on the detected and/or measured operating variables and/or parameters. For example, the sensor device may detect mass, volume, flow rate, temperature, current, pressure, refractive index, thermal conductivity, density, viscosity, absorbance, electrical conductivity, and/or other suitable variables and/or parameters. In some embodiments, the sensor device may detect one or more trigger events (trigger events).
For example, the sensor device 376 may include one or more sensors 380 configured to detect pressure, temperature, flow rate, volume, and/or other parameters. The sensors 380 may, for example, include at least one buffer tank sensor 382 configured to detect one or more suitable operating variables, parameters, and/or triggering events in the buffer tank. The buffer tank sensor may be configured to detect, for example, a pressure in the buffer tank and/or generate one or more signals based on the detected pressure. For example, unless product hydrogen is withdrawn from the buffer tank at a flow rate equal to or greater than the incoming flow rate into the buffer tank, the pressure in the buffer tank may increase and a tank sensor may detect the increase in pressure in the buffer tank.
The control device 378 may include any device configured to control the fuel processing device 358 based at least in part on input from the sensors 376, such as based at least in part on operating variables and/or parameters detected and/or measured by the sensors. Control 378 may receive input from only sensor 376 or it may receive input from other sensor devices of the hydrogen plant.
In some embodiments, fuel processing plant 358 may include a hydrogen generator reactor 366 (such as hydrogen-producing region 385) adjacent to fuel processing plant 358 and a hydrogen-selective membrane 387 and/or a plurality of heaters 383 in thermal communication therewith. The heater may be internal or external to the fuel processor housing. In those embodiments, the control device may communicate with and/or operate the heater to maintain the hydrogen-producing region and/or the hydrogen-selective membrane at a predetermined temperature or temperature range when the fuel processing apparatus is in the standby mode. For example, the heater may maintain the hydrogen-producing region and the hydrogen-selective membrane at 300 to 450 ℃.
The standby mode may sometimes be referred to as a "hot standby mode" or "hot standby state" when the heater is used to maintain the hydrogen-producing region and hydrogen-selective membrane at an elevated temperature. The fuel processing plant is capable of producing a product hydrogen stream from a hot standby mode to an operating mode in a shorter period of time than if the fuel processing plant were started from an off mode or a shutdown state. For example, when switching from a hot standby mode to an operating mode, the fuel processing device is capable of producing a product hydrogen stream in about 5 minutes.
Control device 378 may control only the fuel processing device or the control device may control one or more other components of the hydrogen plant. The control device may communicate with the sensor device, the fuel processing device, the product valve device (described further below), and/or the return valve device (described further below) via a communication link 384. The communication link 384 may be any suitable wired and/or wireless mechanism of single or dual channel communication between corresponding devices, such as input signals, command signals, measured parameters, and the like.
The control device 378 may, for example, be configured to operate the fuel processing device 358 between an operating mode and a standby mode based at least in part on the detected pressure in the surge tank 372. For example, control 378 may be configured to operate the fuel processing device in a standby mode when the detected pressure in the surge tank is above a predetermined maximum pressure and/or in a run mode when the detected pressure in the surge tank is below a predetermined minimum pressure.
The predetermined maximum and minimum pressures may be any suitable maximum and minimum pressures. Those predetermined pressures may be set independently or without regard to other predetermined pressures and/or other predetermined variables. For example, the predetermined maximum pressure may be set according to an operating pressure range of the fuel processing device, such as an overpressure in the fuel processing device due to a back pressure of a product hydrogen management system. In addition, the predetermined minimum pressure may be set according to a pressure required by the hydrogen consuming apparatus. Or alternatively, the control 378 may operate the fuel processing device to operate in a run mode within a predetermined pressure differential (such as between the fuel processing device and the surge tank and/or between the surge tank and the hydrogen-consuming device) and a standby mode outside of the predetermined pressure differential.
In some embodiments, the product hydrogen management system 360 may include a product valve assembly 386, which may include any suitable structure configured to manage and/or direct the flow in the product conduit 370. For example, the product valve arrangement may enable a product hydrogen stream to flow from the fuel processing apparatus to the surge tank, as shown at 388. Additionally, product valve assembly 386 may be configured to vent a product hydrogen stream 362 from fuel processing assembly 358, as shown at 390. The vented product hydrogen stream may be vented to the atmosphere and/or a vented product hydrogen management system (not shown).
Product valve arrangement 386 may, for example, include one or more valves 392 configured to operate between a flow position, in which a product hydrogen stream from the fuel processing arrangement flows through a product conduit and into a surge tank, and a bleed position, in which the product hydrogen stream from the fuel processing arrangement is bled off. Valve 392 may be disposed in any suitable portion of the product conduit prior to the surge tank.
The control device 378 may be configured to operate the product valve device based on input from, for example, a sensor device. For example, when the fuel processing apparatus is in a standby mode, the control apparatus may instruct or control the product valve apparatus (and/or valve 392) to vent a stream of product hydrogen from the fuel processing apparatus. Additionally, when the fuel processor 358 is in the run mode and/or reduced output mode, the control 378 may instruct or control the product valve assembly 386 (and/or valve 392) to allow the product hydrogen stream to flow from the fuel processor to the surge tank.
In some embodiments, the product hydrogen management system 360 may include a return conduit 394 in fluid communication with the buffer tank 372 and the fuel processing device 358, as shown in fig. 10. For example, a return conduit may fluidly connect a product conduit (such as an adjacent surge tank) and the fuel processing plant, which allows the product hydrogen stream to be returned to the fuel processing plant. The return conduit may be fluidly connected to any suitable portion of the fuel processing apparatus. For example, when the fuel processing apparatus includes the hydrogen-producing region 78, one or more hydrogen-purification (or hydrogen-selective) membranes 116, and a reformate conduit 396 fluidly connecting the hydrogen-producing region and the hydrogen-selective membranes, the return conduit 394 may fluidly connect the buffer tank and the reformate conduit, as shown in FIG. 2. Although the return conduit is shown connected downstream of the hot gas filter 114, the return conduit may be connected upstream of the hot gas filter and/or other suitable portions of the fuel processing apparatus.
In embodiments including the return conduit 394, the product hydrogen management system 360 may further include a return valve arrangement 398, which may include any suitable structure configured to manage and/or indicate flow in the return conduit 394. For example, a return valve arrangement may allow a product hydrogen stream to flow from the surge tank to the fuel processing device, as shown at 400.
The return valve arrangement 398 may, for example, include one or more valves 402 configured to operate between an open position, in which the product hydrogen stream from the surge tank flows through the return conduit and into the fuel processing arrangement, and a closed position, in which the product hydrogen stream from the surge tank does not flow through the return conduit and into the fuel processing arrangement. Valve 402 may be disposed in any suitable portion of the return conduit prior to the fuel processing device.
Control device 378 may be configured to operate the return valve device based on input from, for example, a sensor device. For example, the control device may instruct or control the return valve device (and/or valve 402) to allow the product hydrogen stream to flow from the buffer tank to the fuel processing device when the fuel processing device 358 is in a standby mode. In some embodiments, the control device may instruct or control the return valve device and/or valve 402 to allow the product hydrogen stream to flow from the buffer tank to the fuel processing device for one or more predetermined times (periods) and/or at one or more predetermined time intervals to instruct or control the return valve device and/or valve 402 to allow the product hydrogen stream to flow from the buffer tank to the fuel processing device when the fuel processing device is in the standby mode. The predetermined time and/or time interval may be based on preventing or minimizing flow of the product hydrogen stream to components of the fuel processing device other than the hydrogen-selective membrane and/or preventing flow of the product hydrogen stream to those components. For example, the predetermined duration may be 0.1 to 10 seconds when the valve is in the open position, and the predetermined time interval may be 1 to 12 hours. When the predetermined time is from 0.1 to 10 seconds, the introduction of the product hydrogen stream into the fuel processing device, such as upstream of the hydrogen-selective membrane, may sometimes be referred to as a "hydrogen burp".
Another example of a hydrogen-producing assembly 20 is generally shown at 404 in fig. 11. Unless specifically excluded, hydrogen-producing assembly 404 may include one or more components of one or more other hydrogen-producing assemblies described in this disclosure. The hydrogen-producing assembly may provide or supply hydrogen to one or more hydrogen-consuming devices 406, such as fuel cells, hydrogen furnaces, and the like. Hydrogen generation assembly 404 may, for example, include a fuel processing assembly 408 and a product hydrogen management system 410. Fuel processing plant 408 may include any suitable structure configured to generate one or more product hydrogen streams 416 (such as one or more hydrogen streams) from one or more feed streams 418 via one or more suitable mechanisms.
Product hydrogen management system 410 may include any suitable structure configured to manage the product hydrogen generated by fuel processing device 408. Additionally, the product hydrogen management system may include any suitable structure configured to interact with fuel processing device 408 to maintain any suitable amount of product hydrogen available to hydrogen-consuming equipment 406. For example, the product hydrogen management system 410 may include a product conduit 420, a surge tank 422, a surge tank conduit 424, a surge tank sensor arrangement 426, a product valve arrangement 428, a return conduit 430, a return valve arrangement 432, and a control arrangement 434.
The product conduit 420 may be configured to fluidly communicate the fuel processing apparatus 408 with a surge tank 422. The product conduit may include any suitable number of valves, such as check valves (such as check valve 436), control valves, and/or other suitable valves. Check valve 436 may prevent backflow from the surge tank to the fuel processing device. The check valve may open at any suitable pressure, such as 1psi or less. The surge tank 422 may be configured to receive the product hydrogen stream 416 via the product conduit 420 to retain a predetermined two or more volumes of the product hydrogen stream and/or to provide the product hydrogen stream to one or more hydrogen-consuming devices 406.
The buffer tank conduit 424 may be configured to fluidly communicate the buffer tank 422 and the hydrogen-consuming device 406. The surge tank conduit may include any suitable number of valves, such as check valves, control valves, and/or other suitable valves. For example, the surge tank conduit may include one or more control valves 438. Control valve 438 may allow for isolation of the surge tank and/or other components of the hydrogen plant. The control valve may be controlled, for example, by control 434 and/or other control devices.
Tank sensor arrangement 426 may include any suitable structure configured to detect and/or measure one or more suitable operating variables and/or parameters in the surge tank and/or generate one or more signals based on the detected and/or measured operating variables and/or parameters. For example, the buffer tank sensor arrangement may detect mass, volume, flow rate, temperature, current, pressure, refractive index, thermal conductivity, density, viscosity, absorbance, electrical conductivity, and/or other suitable variables and/or parameters. In some embodiments, the buffer tank sensor arrangement can detect one or more triggering events. For example, buffer tank sensor arrangement 426 may include one or more tank sensors 440 configured to detect pressure, temperature, flow rate, volume, and/or other parameters. The buffer tank sensor 440 may, for example, be configured to detect a pressure in the buffer tank and/or generate one or more signals based on the detected pressure.
The product valve assembly 428 may include any suitable structure configured to manage and/or indicate flow in the product conduit 420. For example, the product valve assembly may allow a product hydrogen stream to flow from the fuel processing assembly to the surge tank, as shown at 442. Additionally, product valve assembly 428 can be configured to vent product hydrogen stream 416 from fuel processing assembly 408, as shown at 444. The bleed product hydrogen stream may be vented to atmosphere and/or a bleed product hydrogen management system (not shown), including venting the bleed product hydrogen back to the fuel processing apparatus in addition to (or in lieu of) the return valve apparatus.
The product valve assembly 428 may, for example, include a three-way solenoid valve 446. The three-way solenoid valve may include a solenoid valve 448 and a three-way valve 450. The three-way valve may be configured to move between a plurality of positions. For example, the three-way valve 450 may be configured to move between a flow position and a drain position. In the flow position, a product hydrogen stream is allowed to flow from the fuel processing apparatus to the surge tank, as shown at 442. At the bleed position, the product hydrogen stream from the fuel processing plant is bled off, as shown at 444. Additionally, the three-way valve may be configured to isolate the surge tank from the product hydrogen stream when the valve is in the bleed position. The solenoid valve 448 may be configured to move the valve 450 between the flow and bleed positions based on input received from the control device 434 and/or other control devices.
The return conduit 430 may be configured to fluidly communicate the buffer tank 422 with the fuel processing plant 408 (such as a reformate conduit of the fuel processing plant). The return conduit may include any suitable number of valves, such as a check valve (such as check valve 454), a control valve, and/or other suitable valves. The check valve 454 may organize the return flow from the fuel processing device to the surge tank. The check valve may open at any suitable pressure. In some embodiments, the return conduit 430 may include a flow restriction aperture 456 configured to restrict flow therethrough. The flow restriction orifice may be upstream or downstream of a solenoid valve of the return valve arrangement. Additionally, restrictor aperture 456 may be any suitable size, such as 0.005 inches to 0.035 inches, with 0.010 inches being preferred.
The return valve device 432 may include any suitable structure configured to manage and/or indicate flow in the return conduit 430. For example, a return valve arrangement may allow the product hydrogen stream to flow from the surge tank to the fuel processing device, as shown at 458. Return valve device 432 may, for example, include a solenoid valve 460. The solenoid valves may include a solenoid valve 462 and a valve 464. The valve may be configured to move between a plurality of positions. For example, the valve 464 may be configured to move between an open position and a closed position. When in the open position, a product hydrogen stream is allowed to flow from the surge tank to the fuel processing apparatus, as shown at 458. When in the closed position, the product hydrogen stream is not allowed (or restricted) to flow from the surge tank to the fuel processing apparatus. Additionally, the valve may be configured to isolate the surge tank when the valve is in the closed position. The solenoid valve 462 may be configured to move the valve 464 between open and closed positions based on input from the control 434 and/or other control devices.
Control device 434 may include any suitable structure configured to control fuel treatment device 408, product valve device 428, and/or return valve device 432 based at least in part on input from surge tank sensor device 426, such as based at least in part on operating variables and/or parameters detected and/or measured by the surge tank sensor device. Control device 434 may receive input only from surge tank sensor device 426 and/or the control device may receive input from other sensor devices of the hydrogen plant. In addition, control device 434 can control the fuel processing device only, the product valve device only, the return valve device only, the fuel processing device and the product valve device only, the fuel processing device and the return valve device only, the product valve device and the return valve device only, or one or more other components of the fuel processing device, the product valve device and/or the hydrogen plant. The control device 434 may communicate with the fuel processing device, the surge tank sensor device, the product valve device, and/or the return valve device via a communication link 466. The communication link 466 may be any wired and/or wireless mechanism suitable for single or dual channel communication between respective devices, such as input signals, command signals, measured parameters, and the like.
The control device 434 may, for example, be configured to operate the fuel processing device in or between run and standby modes (and/or reduced output modes) based at least in part on the detected pressure in the surge tank 438. For example, the control device 434 may be configured to operate the fuel treatment device in a standby mode when the detected pressure in the surge tank is greater than a predetermined maximum pressure, in a reduced output mode when the detected pressure in the surge tank is below the predetermined maximum pressure and/or above a predetermined operating pressure, and/or in a run mode when the detected pressure in the surge tank is below the predetermined operating pressure and/or a predetermined minimum pressure. The predetermined maximum and minimum pressures and/or the predetermined operating pressure may be any suitable pressure. For example, one or more of the above pressures may be independently set based on the desired pressure range of the product hydrogen in the fuel processing plant, the surge tank, and/or the pressure requirements of the hydrogen-consuming equipment. Or alternatively, the control device 434 may operate the fuel processing device so that it operates in the run mode within a predetermined range of pressure differentials (such as between the fuel processing device and the surge tank), and operates in the reduced output and/or standby mode when outside of the predetermined range of pressure differentials.
Additionally, the control device 434 may be configured to operate the product valve device based on input from, for example, the sensor 426. For example, when the fuel processing apparatus is in a standby mode, the control apparatus may instruct or control the solenoid valve 448 to move the three-way valve 450 to the bleed position. Additionally, the control device 434 may instruct or control the solenoid valve to move the three-way valve 450 to the flow position when the fuel processing device 408 is in the run mode.
Further, control device 434 may be configured to operate the return valve device based on input from, for example, sensor 426. For example, when the fuel processing apparatus is in a standby mode, the control device may instruct or control the solenoid valve 462 to move the valve 464 to an open position. The control 434 may move the valve 464 to the open position for a predetermined time and/or at predetermined time intervals. Additionally, the control device 434 may instruct or control the solenoid valve 462 to move the valve 464 to the closed position outside of the predetermined time and/or predetermined time interval and/or when the fuel processing device is in the run mode.
The control device 434 may include a first control mechanism 468 and a second control mechanism 470. The first control mechanism may be in communication with, for example, the fuel processing device, the surge tank sensor device, and the product valve device, and/or may be configured to control the product valve device. Second control mechanism 470 may be in communication with, for example, a fuel processing device and a return valve device, and/or may be configured to control the return valve device. Although control device 434 is shown to include first and second control mechanisms 468 and 470, the control device may include a single control mechanism configured to provide most or all of the functionality of the first and second control mechanisms.
The first control mechanism 468 may, for example, include a first controller 472, a first switching device 474, and a first energy supply 476. The first controller 472 may have any suitable form, such as a computerized device, software executing on a computer, an embedded processor, a simulation device, and/or a functionally equivalent device. Additionally, the first processor may include any suitable software, hardware, and/or firmware.
The first switching device 474 may include any suitable structure configured to allow the first controller 472 to control the solenoid valve 448. For example, the switching device may include a first solid state relay or a first SSR 478. The first solid state relay may allow the first controller 472 to control the solenoid 448 via the first energy supply 476. For example, when the solenoid valve 448 is controlled with 24 volts, the solid state relay may allow the first controller 472 to control the solenoid valve 448 using a voltage signal other than 24 volts (e.g., 5 volts, 12 volts, 48 volts, etc.). The first energy supply 476 may comprise any suitable structure configured to provide an energy source sufficient to control the solenoid 448. For example, the first energy supply 476 may include one or more batteries, one or more solar panels, and the like. In some embodiments, the energy supply may include one or more socket connectors (electrical outlet connectors) and one or more rectifiers (not shown). Although the first solenoid valve and the first controller are described as operating at certain voltages, the first solenoid valve and the first controller may operate at any suitable voltages.
Second control mechanism 470 may, for example, include a second controller 480, a second switching device 482, and a second energy supply 484. The second controller 480 may have any suitable form, such as a computerized device, software executing on a computer, an embedded processor, a simulation device, and/or a functionally equivalent device. Additionally, the processor may include any suitable software, hardware, and/or firmware. For example, the second controller 480 may include a time delay relay as follows: a time delay relay that provides a signal to the solenoid valve 462 to move the valve 464 to the open position for a predetermined time and/or at predetermined time intervals. The time delay relay may be energized, for example, only when the fuel processing device is in a standby mode.
The second switching device 482 may comprise any suitable structure configured to allow the second controller 480 to control the solenoid valve 462. For example, the second switching device may include a second solid state relay or second SSR 486. The second solid state relay may allow the second controller 480 to control the solenoid valve 462 via the second energy supply 484. For example, when the solenoid valve 462 is controlled with 24 volts, the solid state relay may allow the second controller 480 to control the second solenoid valve 462 using a non-24 volt (such as 5 volts, 12 volts, 48 volts, etc.) signal. The second energy supply 484 can include any suitable structure configured to provide an energy source sufficient to control the solenoid valve 462. For example, second energy supply 484 may include one or more batteries, one or more solar panels, and the like. In some embodiments, the second energy supply may include one or more socket connectors and one or more rectifiers (not shown). Although the second solenoid valve and the second controller are described as operating at certain voltages, the second solenoid valve and the second controller may operate at any suitable voltages.
In some embodiments, the first and/or second control mechanisms (or components of those mechanisms) may be configured to control other components of the hydrogen plant and/or may be incorporated with other control mechanisms and/or control devices. For example, the first and second control mechanisms may share an energy supply. Additionally, the second control mechanism may be configured to control operation of heaters in thermal communication with the hydrogen-producing region and the hydrogen-selective membrane and/or may be connected to a control device that controls those heaters.
Another example of a hydrogen plant 20 is generally shown at 488 in fig. 12. Unless specifically excluded, hydrogen-producing assembly 488 may include one or more components of one or more other hydrogen-producing assemblies described in this disclosure. Components of hydrogen-producing assembly 488 that are similar or identical to components of hydrogen-producing assembly 404 in fig. 11 are provided with the same reference numerals as the components of hydrogen-producing assembly 404. Since those components have been discussed previously, this portion of the disclosure focuses on components other than hydrogen-producing assembly 404.
Product conduit 420 may include a flow portion or branch (leg)489 and a bleed portion or branch 491. Hydrogen production device 488 may include a product valve device 490 that may include any suitable structure configured to manage and/or direct flow in product conduit 420. For example, the product valve assembly may allow the product hydrogen stream 416 to flow from the fuel processing assembly to a surge tank (as shown at 442) and/or the product hydrogen stream 416 to bleed from the fuel processing assembly 408 (as shown at 444). The vented product hydrogen stream may be vented to the atmosphere and/or a vented product hydrogen management system (not shown).
The product valve arrangement 490 may, for example, include a first solenoid valve 492 and a second solenoid valve 494. The first solenoid may include a first solenoid 496 and a first valve 498, while the second solenoid may include a second solenoid 500 and a second valve 502. The first valve may be configured to move between a plurality of positions including a first open position and a first closed position. Additionally, the second valve may be configured to move between a plurality of positions including a second open position and a second closed position.
When the first valve is in the open position, a product hydrogen stream is allowed to flow from the fuel processing apparatus to the surge tank. Conversely, when the first valve is in the closed position, the surge tank is isolated from the product hydrogen stream from the fuel processing apparatus (or the product hydrogen stream from the fuel processing apparatus is not allowed to flow to the surge tank). When the second valve is in the open position, the product hydrogen stream from the fuel processing device is vented. Conversely, when the second valve is in the closed position, the product hydrogen stream from the fuel processing device is not vented.
The first solenoid valve 496 may be configured to move the first valve 498 between an open and closed position based on input received from the control device 434. Additionally, the second solenoid valve 500 may be configured to move the second valve 502 between open and closed positions based on input received from the control device.
The control device 434 may be configured to operate the product valve device based on, for example, input from a sensor device. For example, the control device may instruct or control the first and/or second solenoid valves to move the first valve to the closed position and/or the second valve to the open position when the fuel processing device is in the standby mode. Additionally, the control device 434 may instruct or control the first and/or second solenoid valves to move the first valve to the open position and/or the second valve to the closed position when the fuel processing device 408 is in the run mode and/or the reduced output mode.
The hydrogen generation apparatus of the present disclosure may include one or more of the following:
a first and second end frame comprising an input port configured to receive a mixed gas stream comprising hydrogen and other gases.
A first and second end frame comprising an outlet configured to receive a permeate stream comprising at least one of a higher concentration of hydrogen and a lower concentration of other gases than the mixed gas stream.
A first and second end frames comprising a byproduct port configured to receive a byproduct stream comprising at least a majority of the other gases.
O at least one hydrogen-selective membrane disposed between and secured to the first and second end frames.
O at least one hydrogen-selective membrane having a feed side and a permeate side, at least a portion of the permeate stream being formed by a portion of the mixed gas stream passing from the feed side to the permeate side, and the remainder of the mixed gas stream remaining on the feed side forming at least a portion of the by-product stream.
A plurality of frames disposed between and secured to the first and second end frames and the at least one hydrogen-selective membrane.
A plurality of frames comprising at least one permeable frame disposed between the at least one hydrogen-selective membrane and the second end frame.
At least one infiltration frame comprising a peripheral shell.
At least one permeate frame comprising an output conduit formed on the peripheral housing and configured to receive at least a portion of the permeate stream from the at least one hydrogen-selective membrane.
At least one permeable frame comprising an open area surrounded by a peripheral shell.
At least one permeable frame comprising at least one membrane support structure.
At least one membrane support structure spanning at least a majority of the open area.
At least one membrane support structure configured to support at least one hydrogen-selective membrane.
At least one membrane support structure comprising first and second membrane support plates.
O first and second membrane support plates that are free of perforations.
O first and second membrane support plates having a first face with a plurality of microchannels configured to provide flow channels for at least a portion of the permeate stream.
O first and second membrane support plates having a second face opposite the first face.
O first and second membrane support plates stacked in at least one membrane support structure.
O first and second membrane support plates stacked in the at least one membrane support structure such that the second face of the first membrane support plate faces the second face of the second membrane support plate.
O incompressible first and second membrane support plates.
O flat first and second membrane support plates.
O at least one feed frame disposed between the first end frame and the at least one hydrogen-selective membrane.
At least one feed frame comprising a peripheral shell.
O at least one feed frame comprising an input conduit formed on a peripheral shell of the at least one feed frame.
At least one feed frame comprising an input conduit configured to receive at least a portion of the mixed gas stream from the input port.
O at least one feed frame comprising an output conduit formed on a peripheral shell of the at least one feed frame.
At least one feed frame comprising an output conduit configured to receive a remaining portion of the at least a portion of the mixed gas stream remaining on the feed side of the at least one hydrogen-selective membrane.
O at least one feed frame comprising a feed frame arranged between the input and output conduits surrounded by a peripheral casing of the feed frame.
O a peripheral shell of at least one feed frame, dimensioned such that the peripheral shell of the at least one feed frame supports the peripheral shell of the at least one permeate frame and a portion of the at least one membrane support structure.
O a peripheral shell of at least one feed frame, dimensioned such that the peripheral shell of the at least one feed frame supports the peripheral shell of the at least one permeate 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.
O at least one microsieve structure disposed between the at least one hydrogen-selective membrane and the at least one permeable frame.
At least one microsieve structure configured to support at least one hydrogen-selective membrane.
At least one microsieve structure comprising generally opposing surfaces configured to provide support to a permeate side.
At least one microsieve structure comprising a plurality of fluid passageways extending between opposing surfaces.
O at least one microsieve structure dimensioned to not contact the peripheral shell of the at least one infiltration frame.
O at least one microsieve structure dimensioned so as not to contact the peripheral housing when the at least one microsieve structure and the at least one permeable frame are fastened to the first and second end frames.
At least one membrane support structure comprising a third membrane support plate.
A third membrane support plate disposed between the first and second membrane support plates.
An incompressible third membrane support plate.
O flat third membrane support plate.
A third membrane support plate that is free of perforations.
A third membrane support plate, which is free of microgrooves.
An outer peripheral shell of the osmotic frame, comprising a first and a second outer peripheral shell.
An outer peripheral shell of the osmotic frame, comprising a liner arranged between the first and second outer peripheral shells.
O-pad configured such that the thickness of the peripheral shell of the permeate frame matches the thickness of the membrane support structure.
O-pad configured such that when the permeate frame is fastened to the first and second end frames, the thickness of the peripheral shell of the permeate frame matches the thickness of the membrane support structure.
An outer peripheral shell of the osmotic frame, comprising a first, a second and a third outer peripheral shell.
An outer peripheral shell of the osmotic frame, comprising a first liner arranged between a first and a second outer peripheral shell.
An outer peripheral shell of the osmotic frame, comprising a second liner arranged between the second and third outer peripheral shells.
O first and second liners configured such that the thickness of the peripheral shell of the permeate frame matches the thickness of the membrane support structure.
O first and second liners configured such that the thickness of the peripheral shell of the permeate frame matches the thickness of the membrane support structure when the permeate frame is fastened on the first and second end frames.
O first and second membrane support plates each having first and second opposing edges.
A plurality of microgrooves extending from a first edge to a second edge.
Omicron a plurality of parallel microgrooves.
A fuel processing device configured to receive a feed stream.
A fuel processing device configured to operate in a plurality of modes.
A fuel processing device configured to operate in a plurality of modes including an operating mode in which the fuel processing device generates a product hydrogen stream from the feed stream and a standby mode in which the fuel processing device does not generate a product hydrogen stream from the feed stream.
A hydrogen-producing region comprising a reforming catalyst.
A hydrogen-producing region configured to receive a feed stream and produce a reformate stream.
One or more hydrogen-selective membranes configured to receive the reformate stream.
One or more hydrogen-selective membranes configured to produce at least a portion of a product hydrogen stream and a byproduct stream from the reformate stream.
A reformate conduit in fluid communication with the hydrogen-producing region and the one or more hydrogen-selective membranes.
A buffer tank configured to contain a product hydrogen stream.
A product conduit fluidly communicating the fuel processing device with the buffer tank.
A return conduit fluidly communicating the buffer tank and the reformate conduit.
A canister sensor device configured to detect pressure in the buffer canister.
-a backflow valve device configured to manage flow in the backflow conduit.
-a backflow valve device, comprising at least one valve.
At least one valve configured to operate between an open position, where the product hydrogen stream from the buffer tank flows through the return conduit and into the reformate conduit, and a closed position, where the product hydrogen stream from the buffer tank does not flow through the return conduit and into the reformate conduit.
A plurality of heaters in thermal communication with the hydrogen-producing region and the one or more hydrogen-selective membranes.
A control device configured to operate the fuel processing device between an operating mode and a standby mode.
A control device configured to operate the fuel processing device between an operating mode and a standby mode based at least in part on the detected pressure in the buffer tank.
A control device configured to instruct the return valve device to allow the product hydrogen stream to flow from the buffer tank to the reformate conduit.
A control device configured to instruct the return valve device to allow the product hydrogen stream to flow from the buffer tank to the reformate conduit when the fuel processing device is in a standby mode.
A control device configured to instruct the reflux device to allow the product hydrogen stream to flow from the buffer tank to the reformate conduit at one or more predetermined time intervals.
A control device configured to instruct the return device to allow the flow of the product hydrogen stream from the buffer tank to the reformate conduit at one or more predetermined time intervals when the fuel processing device is in the standby mode.
A control device configured to instruct the reflux device to allow the product hydrogen stream to flow from the buffer tank to the reformate conduit for a predetermined time at one or more predetermined time intervals.
A control device configured to instruct the return device to allow the flow of the product hydrogen stream from the buffer tank to the reformate conduit for a predetermined time at one or more predetermined time intervals when the fuel processing device is in the standby mode.
A control device configured to move the at least one valve to the open position for a predetermined time at predetermined time intervals.
A control device configured to move the at least one valve to the open position for a predetermined time at predetermined time intervals when the fuel treatment device is in the standby mode.
A control device configured to operate the plurality of heaters to maintain the hydrogen-producing region and the one or more hydrogen-selective membranes within a predetermined temperature range.
A control device configured to operate the plurality of heaters to maintain the hydrogen-producing region and the one or more hydrogen-selective membranes within a predetermined temperature range when the fuel treatment device is in a standby mode.
Industrial applicability
The present disclosure includes hydrogen-producing devices, hydrogen-purification devices, and components of those devices and devices, which may be used in fuel-processing and other industries in which hydrogen gas is purified, produced, and/or utilized.
The disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and/or properties disclosed herein. Similarly, where any claim recites "a" or "a first" element or the equivalent thereof, such claim should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.
Inventions embodied in various combinations and subcombinations of features, functions, elements, and/or properties may be claimed through presentation of new claims in a related application. Such new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.