Hydrogen purification devices, components, and fuel processing systems containing the same

Abstract

Hydrogen purification devices, components thereof, and fuel processors and fuel cell systems containing the same. The hydrogen purification devices include an enclosure, such as a pressure vessel, that contains a separation assembly that receives under pressure a mixed gas stream containing hydrogen gas and produces a stream that contains pure or at least substantially pure hydrogen gas therefrom. In some embodiments, the enclosure is sealed without gaskets. The separation assembly includes at least one hydrogen-permeable and/or hydrogen-selective membrane. In some embodiments the hydrogen-selective membrane is permanently and directly secured to the enclosure or a perimeter shell. In some embodiments, the membrane is welded, diffusion bonded or brazed directly to the enclosure or shell. In some embodiments, a portion of the membrane forms a portion of a seal and/or the sealed enclosure. In some embodiments, an interface is formed from consumed portions of the hydrogen-selective membrane and the enclosure or shell.

1 . A hydrogen purification device, comprising: 
 an enclosure defining a pressure vessel with an internal compartment, wherein the device is configured to receive into the compartment a mixed gas stream comprising hydrogen gas and other gases, and to produce therefrom a hydrogen-rich permeate stream containing at least substantially pure hydrogen gas and a byproduct stream containing at least a substantial portion of the other gases, wherein the enclosure includes at least one perimeter shell; and    at least one hydrogen-selective membrane permanently and directly secured to the at least one perimeter shell to form a seal therewith and extending within the compartment to divide the compartment into at least one mixed gas region and at least one permeate region, wherein the at least one membrane includes a mixed gas surface configured to be contacted by the mixed gas stream and a permeate surface generally opposed to the mixed gas surface, wherein the at least one membrane is configured to selectively allow a first portion of the mixed gas stream to pass through the at least one membrane from the at least one mixed gas region to the at least one permeate region and to restrict a second portion of the mixed gas stream from passing through the at least one membrane from the at least one mixed gas region to the at least one permeate region, and wherein the permeate stream is formed from the first portion of the mixed gas stream, and the byproduct stream is formed from the second portion of the mixed gas stream.    
     
     
         2 . The device of  claim 1 , wherein the at least one hydrogen-selective membrane is permanently and directly secured to the perimeter shell by a destructive bonding process in which portions of the membrane and the perimeter shell are consumed to form an alloy.  
     
     
         3 . The device of  claim 1 , wherein the at least one hydrogen-selective membrane is welded to the at least one perimeter shell.  
     
     
         4 . The device of  claim 1 , wherein the at least one hydrogen-selective membrane is at least one of brazed and diffusion bonded to the at least one perimeter shell.  
     
     
         5 . The device of  claim 1 , further comprising at least one interface formed from consumed portions of the at least one hydrogen-selective membrane and the at least one perimeter shell.  
     
     
         6 . The device of  claim 5 , wherein the consumed portion of the at least one hydrogen-selective membrane forms an alloy with the consumed portion of the at least one perimeter shell.  
     
     
         7 . The device of  claim 1 , wherein the at least one perimeter shell is separately formed from a portion of the enclosure.  
     
     
         8 . The device of  claim 7 , wherein the at least one perimeter shell is secured to a portion of the enclosure to form a gas-tight seal therewith.  
     
     
         9 . The device of  claim 8 , wherein the gas-tight seal is formed by welding the at least one perimeter shell to a portion of the enclosure.  
     
     
         10 . The device of  claim 9 , wherein the gas-tight seal is formed by laser welding the at least one perimeter shell to the portion of the enclosure.  
     
     
         11 . The device of  claim 9 , further comprising at least one interface formed from consumed portions of the at least one perimeter shell and the portion of the enclosure.  
     
     
         12 . The device of  claim 11 , wherein the consumed portion of the at least one perimeter shell forms an alloy with the consumed portion of the portion of the enclosure.  
     
     
         13 . The device of  claim 8 , further comprising at least one gasket disposed between the at least one perimeter shell and the portion of the enclosure and configured to form the gas-tight seal.  
     
     
         14 . The device of  claim 13 , wherein the portion of the enclosure includes a pair of end plates, and wherein the gas-tight seal is formed by compressing the at least one perimeter shell and the at least one gasket between the pair of end plates.  
     
     
         15 . The device of  claim 1 , wherein a first of the at least one membrane is permanently and directly secured to a first of the at least one perimeter shell, and a second of the at least one membrane is permanently and directly secured to a second of the at least one perimeter shell, and wherein the first perimeter shell is secured to the second perimeter shell to form a gas-tight seal therewith.  
     
     
         16 . The device of  claim 15 , further comprising one or more gaskets disposed between the first perimeter shell and the second perimeter shell.  
     
     
         17 . A hydrogen purification device, comprising: 
 an enclosure defining a pressure vessel with an internal compartment, wherein the device is configured to receive into the compartment a mixed gas stream comprising hydrogen gas and other gases, and to produce therefrom a hydrogen-rich permeate stream containing at least substantially pure hydrogen gas and a byproduct stream containing at least a substantial portion of the other gases;    at least one perimeter frame;    at least one hydrogen-selective membrane disposed at least substantially within the internal compartment, wherein each of the at least one hydrogen-selective membranes is secured to at least one of the at least one perimeter frames at an interface to form a seal therewith, wherein the interface includes consumed portions of the at least one hydrogen-selective membrane and the at least one perimeter frame, wherein each of the at least one hydrogen-selective membranes includes a mixed gas surface configured to be contacted by the mixed gas stream and a permeate surface generally opposed to the mixed gas surface, wherein the permeate stream is formed from a portion of the mixed gas stream that passes through the at least one hydrogen-selective membrane, and the byproduct stream is formed from a portion of the mixed gas stream that does not pass through the at least one hydrogen-selective membrane.    
     
     
         18 . The device of  claim 17 , wherein the at least one perimeter frame forms a portion of the enclosure.  
     
     
         19 . A method of forming a hydrogen purification device, comprising: 
 permanently and directly securing a hydrogen-selective membrane to a perimeter frame with a destructive bonding process in which at least a portion of the membrane is consumed to form a seal with the perimeter frame; and    forming an enclosure containing the perimeter frame, wherein the enclosure includes an internal compartment within which the secured hydrogen-selective membrane extends to divide the internal compartment into a mixed gas region and a permeate region.    
     
     
         20 . The method of  claim 19 , wherein permanently and directly securing the hydrogen-selective membrane includes welding the hydrogen-selective membrane to the perimeter frame.  
     
     
         21 . The method of  claim 19 , wherein the hydrogen-selective membrane is a first hydrogen-selective membrane, wherein the method further comprises repeating the permanently and directly securing step for at least a second hydrogen-selective membrane, and further wherein the forming step includes forming an enclosure with an internal compartment within which the first hydrogen-selective membrane and the second hydrogen-selective membrane extend.  
     
     
         22 . The method of  claim 19 , wherein the hydrogen-selective membrane is a first hydrogen-selective membrane, wherein the perimeter frame is a first perimeter frame, wherein the method further comprises repeating the permanently and directly securing step for at least a second hydrogen-selective membrane and a second perimeter frame, and further wherein the forming step includes forming an enclosure containing the first perimeter frame and the second perimeter frame and in which the first hydrogen-selective membrane and the second hydrogen-selective membrane extend within the internal compartment.  
     
     
         23 . The method of  claim 19 , wherein the method further includes forming a gas-tight seal with one or more other portions of the enclosure to form a sealed enclosure.  
     
     
         24 . The method of  claim 23 , wherein the method includes installing one or more gaskets between the perimeter frame and the one or more other portions of the enclosure.  
     
     
         25 . The method of  claim 19 , wherein the enclosure includes a pair of end plates, and further wherein the perimeter frame extends between the pair of end plates.