US-12623181-B2 - Hydrogen purification devices

US12623181B2US 12623181 B2US12623181 B2US 12623181B2US-12623181-B2

Abstract

Hydrogen purification devices and their components are disclosed. In some embodiments, the devices may include feed frame(s) and/or permeate frame(s) each having at least one elongate hole distinct and spaced from an open region, at least one output aperture, and/or at least one input aperture. The elongate hole may be disposed between the open region and the at least one input aperture. The elongate hole may be capable of receiving a portion of the mixed gas stream that leaks from the open region and/or at least one input conduit. The devices may additionally include gasket frames having at least one notch in one or more edges of a perimeter base. The notch may be in fluid communication with a longitudinal end portion of the elongate hole. The devices may further include first and second side plates that collectively enclose a plurality of frames.

Inventors

David J. Edlund
Robert Todd Studebaker

Assignees

ELEMENT 1 CORP

Dates

Publication Date: 20260512
Application Date: 20230602

Claims (19)

1 . A hydrogen purification device, comprising: first and second end frames including: an input port capable of receiving a mixed gas stream containing hydrogen gas and other gases; an output port capable of receiving a permeate stream containing at least one of a greater concentration of hydrogen gas and a lower concentration of the other gases than the mixed gas stream; and a byproduct port capable of receiving a byproduct stream containing at least a substantial portion of the other gases; at least one hydrogen-selective membrane disposed between and secured to the first and second end frames, the at least one hydrogen-selective membrane having a feed side and a permeate side, at least part of the permeate stream being formed from the portion of the mixed gas stream that passes from the feed side to the permeate side, with the remaining portion of the mixed gas stream, which remains on the feed side, forming at least part of the byproduct stream; and a plurality of frames disposed between the first and second end frames and the at least one hydrogen-selective membrane and secured to the first and second end frames, the plurality of frames including a feed frame disposed between the at least one hydrogen-selective membrane and one of the first and second end frames, the feed frame including: a planar perimeter shell, an open region surrounded by the perimeter shell, the open region being in fluid communication with input apertures of other frames of the plurality of frames, the input apertures collectively forming at least one input conduit, and the open region and the at least one input conduit capable of receiving at least a portion of the mixed gas stream, at least one output aperture in the perimeter shell, the at least one output aperture being distinct and spaced from the open region and forming at least one output conduit with corresponding output apertures of other frames of the plurality of frames, and the at least one output conduit capable of receiving at least part of the permeate stream, and at least one elongate hole distinct and spaced from the open region and the at least one output aperture, the at least one elongate hole being disposed between the open region and the at least one output aperture, and the at least one elongate hole being capable of receiving a portion of the mixed gas stream that leaks from the open region or the at least one input conduit.
2 . The device of claim 1 , wherein the plurality of frames includes first and second gasket frames, the feed frame being disposed between the first and second gasket frames, each of the first and second gasket frames including: a planar perimeter base, an open area surrounded by the perimeter base, at least one input aperture in the perimeter base, the at least one input aperture being distinct and spaced from the open area, and the least one input aperture forming a portion of the at least one input conduit, at least one output aperture in the perimeter base, the at least one output aperture being distinct and spaced from the open area and the at least one input aperture, and the at least one output aperture forming a portion of the at least one output conduit with the at least one output aperture of the feed frame, and at least one notch in one or more edges of the perimeter base, the at least one notch being distinct and spaced from the open area, the at least one input aperture, and the at least one output aperture, and the at least one notch being in fluid communication with a longitudinal end portion of the at least one elongate hole of the feed frame.
3 . The device of claim 2 , wherein the plurality of frames further includes a permeate frame, the at least one hydrogen-selective membrane being disposed between the permeate frame and the feed frame, the permeate frame including: a planar perimeter shell, an open region surrounded by the perimeter shell, a support plate received in and spanning a substantial portion of the open region, the support plate being in contact with and supporting the at least one hydrogen selective membrane, the support plate and the perimeter shell defining at least one output aperture therebetween, and the at least one output aperture forming a portion of the at least one output conduit with the at least one output aperture of the feed frame and with the at least one output aperture of the first and second gasket frames, at least one input aperture in the perimeter shell, the at least one input aperture being distinct and spaced from the open region and the at least one output aperture, and the at least one input aperture forming a portion of the at least one input conduit with the input apertures of the first and second gasket frames, and at least one elongate hole distinct and spaced from the open region, the least one output aperture, and the at least one input aperture, the at least one elongate hole being disposed between the open region and the at least one input aperture, and the at least one elongate hole being capable of receiving a portion of the mixed gas stream that leaks from the at least one input conduit.
4 . The device of claim 3 , wherein the at least one notch of the first and second gasket frames is in fluid communication with a longitudinal end portion of the at least one elongate hole of the permeate frame.
5 . The device of claim 4 , wherein the at least one elongate hole of the feed frame extends longitudinally along the perimeter shell of the feed frame, and wherein the at least one elongate hole of the permeate frame extends laterally along the perimeter shell of the permeate frame.
6 . The device of claim 1 , wherein the plurality of frames further includes a permeate frame, the at least one hydrogen-selective membrane being disposed between the permeate frame and the feed frame, the permeate frame including: a planar perimeter shell, an open region surrounded by the perimeter shell, a support plate received in and spanning a substantial portion of the open region, the support plate being in contact with and supporting the at least one hydrogen selective membrane, the support plate and the perimeter shell defining at least one output aperture therebetween, and the at least one output aperture forming a portion of the at least one output conduit with the at least one output aperture of the feed frame, at least one input aperture in the perimeter shell, the at least one input aperture being distinct and spaced from the open region and the at least one output aperture, and the at least one input aperture forming a portion of the at least one input conduit, and at least one elongate hole distinct and spaced from the open region, the least one output aperture, and the at least one input aperture, the at least one elongate hole being disposed between the open region and the at least one input aperture, the at least one elongate hole being capable of receiving a portion of the mixed gas stream that leaks from the at least one input conduit.
7 . The device of claim 1 , further comprising opposed side plates attached to each other and to the first and second end frames, wherein the opposed side plates and the first and second end frames collectively enclose the plurality of frames.
8 . The device of claim 7 , wherein at least one side plate of the opposed side plates includes a mixed gas port capable of receiving the portion of the mixed gas stream that leaks from at least one of the open region of the feed frame and the at least one input conduit.
9 . The device of claim 7 , wherein each of the opposed side plates includes an elongate base member having opposed longitudinal ends, and a side member attached to, or formed with, each of the opposed longitudinal ends.
10 . The device of claim 9 , wherein each side member is perpendicularly attached to, or formed with, a corresponding longitudinal end of the opposed longitudinal ends.
11 . The device of claim 1 , wherein the perimeter shell of the feed frame includes opposed notches in fluid communication with the open region, further comprising at least one membrane support plate having opposed longitudinal end portions received in the opposed notches.
12 . The device of claim 11 , wherein the at least one membrane support plate includes first and second membrane support plates, each of the first and second membrane support plates having a first face having a plurality of grooves capable of providing flow channels for at least a portion of the mixed gas stream, and a second face opposed the first face, wherein the first and second membrane support plates are stacked such that the first face of the first membrane support plate faces the first face of the second membrane support plate.
13 . The device of claim 1 , wherein the at least one elongate hole of the feed frame spans at least 180 degrees around the at least one output aperture of the feed frame.
14 . The device of claim 1 , wherein the at least one elongate hole of the feed frame is spaced from the edges of the perimeter shell of the feed frame.
15 . The device of claim 1 , wherein the at least one elongate hole of the feed frame does not terminate at an edge of the perimeter shell of the feed frame.
16 . The device of claim 1 , wherein the at least one elongate hole of the feed frame includes a first elongate hole and a second elongate hole spaced and distinct and spaced from the first elongate hole.
17 . The device of claim 16 , wherein a substantial portion of the first elongate hole is co-linear with a substantial portion of the second elongate hole.
18 . The device of claim 16 , where the perimeter shell of the feed frame defines a longitudinal axis, wherein an end portion of the second elongate hole is co-axial with an end portion of the first elongate hole along a plurality of lateral axes that are perpendicular to the longitudinal axis.
19 . The device of claim 1 , further comprising at least one microscreen structure having a plurality of microscreen apertures, wherein the at least one hydrogen-selective membrane is metallurgically bonded to the at least one microscreen structure.

Description

BACKGROUND OF THE DISCLOSURE A hydrogen generation assembly is an assembly that converts one or more feedstocks into a product stream containing hydrogen gas as a majority component. The feedstocks may include a carbon-containing feedstock and, in some embodiments, also may include water. The feedstocks are delivered to a hydrogen-producing region of the hydrogen generation assembly from a feedstock delivery system, typically with the feedstocks being delivered under pressure and at elevated temperatures. The hydrogen-producing region is often associated with a temperature modulating assembly, such as a heating assembly or cooling assembly, which consumes one or more fuel streams to maintain the hydrogen-producing region within a suitable temperature range for effectively producing hydrogen gas. The hydrogen generation assembly may generate hydrogen gas via any suitable mechanism(s), such as steam reforming, autothermal reforming, pyrolysis, and/or catalytic partial oxidation. The generated or produced hydrogen gas may, however, have impurities. That gas may be referred to as a mixed gas stream that contains hydrogen gas and other gases. Prior to using the mixed gas stream, it must be purified, such as to remove at least a portion of the other gases. The hydrogen generation assembly may therefore include a hydrogen purification device for increasing the hydrogen purity of the mixed gas stream. The hydrogen purification device may include at least one hydrogen-selective membrane to separate the mixed gas stream into a product stream and a byproduct stream. The product stream contains a greater concentration of hydrogen gas and/or a reduced concentration of one or more of the other gases from the mixed gas stream. Hydrogen purification using one or more hydrogen-selective membranes is a pressure driven separation process in which one or more hydrogen-selective membranes are contained in a pressure vessel. The mixed gas stream contacts the mixed gas surface of the membrane(s), and the product stream is formed from at least a portion of the mixed gas stream that permeates through the membrane(s). The pressure vessel is typically sealed to prevent gases from entering or leaving the pressure vessel except through defined inlet and outlet ports or conduits. The product stream may be used in a variety of applications. One such application is energy production, such as in electrochemical fuel cells. An electrochemical fuel cell is a device that converts fuel and an oxidant to electricity, a reaction product, and heat. For example, fuel cells may convert hydrogen and oxygen into water and electricity. In those fuel cells, the hydrogen is the fuel, the oxygen is the oxidant, and the water is a reaction product. Fuel cell stacks include a plurality of fuel cells and may be utilized with a hydrogen generation assembly to provide an energy production assembly. Examples of hydrogen generation assemblies, hydrogen processing assemblies, and/or components of those assemblies are described in U.S. Pat. Nos. 5,861,137; 6,319,306; 6,494,937; 6,562,111; 7,063,047; 7,306,868; 7,470,293; 7,601,302; 7,632,322; 8,961,627; and U.S. Patent Application Publication Nos. 2006/0090397; 2006/0272212; 2007/0266631; 2007/0274904; 2008/0085434; 2008/0138678; 2008/0230039; and 2010/0064887. The complete disclosures of the above patents and patent application publications are hereby incorporated by reference for all purposes. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of an example of a hydrogen generation assembly. FIG. 2 is a schematic view of an example of the hydrogen generation assembly of FIG. 1. FIG. 3 is a schematic view of a hydrogen purification device of the hydrogen generation assembly of FIG. 1 or FIG. 2. FIG. 4 is an isometric view of an example of the hydrogen purification device of FIG. 3. FIG. 5 is an isometric view of the hydrogen purification device of FIG. 4, shown with illustrative side plates detached. FIG. 6 is an exploded isometric view of the hydrogen purification device of FIG. 4, shown without end frames and shown with one of two foil-microscreen assemblies exploded. FIG. 7 is a partial view of an example of a microscreen support structure of the hydrogen purification device of FIG. 4. FIG. 8 is a partial view of the hydrogen purification device of FIG. 6, showing an example of a feed frame and gasket frames. FIG. 9 is an exploded isometric view of an example of opposed inserts for the feed frame of FIG. 8. FIG. 10 is an exploded isometric view of another example of opposed inserts for the feed frame of FIG. 8. FIG. 11 is a partial sectional view of the feed frame of FIG. 8 taken along lines 11-11 in FIG. 13, showing an example of flow channels provided by the opposed inserts of FIG. 9 or FIG. 10. FIG. 12 is a top view of the feed frame and gasket frames of FIG. 8. FIG. 13 is a top view of the feed frame of FIG. 8 showing an example of flow direction of the mixed gas stream and flow direction of any