TWI892808B - Hydrogen purification devices and foil-microscreen assemblies - Google Patents

Abstract

Hydrogen purification devices and their components are disclosed. In some embodiments, the devices may include at least one foil-microscreen assembly disposed between and secured to first and second end frames. The at least one foil-microscreen assembly may include at least one hydrogen-selective membrane and at least one microscreen structure including a non-porous planar sheet having a plurality of apertures forming a plurality of fluid passages. The planar sheet may include generally opposed planar surfaces configured to provide support to the permeate side. The plurality of fluid passages may extend between the opposed surfaces. The at least one hydrogen-selective membrane may be metallurgically bonded to the at least one microscreen structure.

Description

Hydrogen purification device and foil microporous screen assembly

Cross-reference to related applications: This application is a continuation-in-part of U.S. patent application No. 16/904,872, filed on August 31, 2021, and entitled “Hydrogen Purification Devices,” which is a divisional application of U.S. patent application No. 15/862,474, filed on January 4, 2018, and entitled “Hydrogen Purification Devices,” which is a divisional application of U.S. patent application No. 10,166,506, filed on April 10, 2017, and entitled “Hydrogen Generation Assemblies and Hydrogen Purification Devices.” Devices”, which is a continuation-in-part of U.S. Patent Application No. 15/483,265, filed on November 3, 2015, and issued as U.S. Patent No. 9,616,389, entitled “Hydrogen Generation Assemblies and Hydrogen Purification Devices”, which is a continuation-in-part of U.S. Patent Application No. 14/931,585, filed on March 14, 2013, and issued as U.S. Patent No. 9,187,324, entitled “Hydrogen Generation Assemblies and Hydrogen Purification Devices” No. 13/829,766, entitled “Hydrogen Generation Assemblies,” which is a continuation-in-part of now-deceased U.S. patent application No. 13/600,096, filed on August 30, 2012, and entitled “Hydrogen Generation Assemblies.” The entire disclosure of the foregoing application is hereby incorporated by reference for all purposes.

A hydrogen generation assembly is an assembly that converts one or more feedstocks into a product stream containing hydrogen as a primary component. The feedstocks may include carbonaceous feedstocks and, in some embodiments, may also include water. The feedstocks are delivered from a feedstock delivery system to a hydrogen generation zone of the hydrogen generation assembly, wherein the feedstocks are typically delivered under pressure and at elevated temperatures. The hydrogen generation zone is typically associated with a temperature conditioning assembly, such as a heating assembly or a cooling assembly, which consumes one or more fuel streams to maintain the hydrogen generation zone within a suitable temperature range to efficiently generate hydrogen. The hydrogen generation assembly may generate hydrogen by any suitable mechanism, such as steam reforming, spontaneous thermal reforming, pyrolysis, and/or catalytic partial oxidation.

However, the hydrogen produced or generated may have impurities. That gas may be referred to as a mixed gas stream containing hydrogen and other gases. Before the mixed gas stream is used, it must be purified to remove at least a portion of the other gases. The hydrogen production 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 by-product stream. The product stream contains a larger concentration of hydrogen and/or a smaller concentration of one or more other gases from the mixed gas stream. Hydrogen purification using one or more hydrogen-selective membranes is a pressure-driven separation process in which the membranes are contained within a pressure vessel. A mixed gas stream contacts the mixed gas surface of the membranes, and a product stream is formed from at least a portion of the mixed gas stream that permeates through the membranes. The pressure vessel is typically sealed to prevent gas from entering or leaving the pressure vessel except through defined inlet and outlet ports or conduits.

The product stream can be used in a variety of applications. One such application is energy generation, such as in electrochemical fuel cells. Electrochemical fuel cells are devices that convert fuel and oxidants into electricity, reaction products, and heat. For example, fuel cells can convert hydrogen and oxygen into water and electricity. In these fuel cells, hydrogen is the fuel, oxygen is the oxidant, and water is the reaction product. A fuel cell stack comprises multiple fuel cells and can be used with a hydrogen generation assembly to provide an energy generation assembly.

Examples of hydrogen generation assemblies, hydrogen processing assemblies, and/or components thereof are described in U.S. Patents 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; No. 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 entire disclosures of the above patents and patent application publications are hereby incorporated by reference for all purposes.

The present invention relates to a hydrogen purification device comprising: a first end frame and a second end frame, comprising: an input port configured to receive a mixed gas stream containing hydrogen and other gases; an output port configured to receive a permeate stream containing a greater concentration of hydrogen and a lower concentration of at least one of the other gases than the mixed gas stream; and a byproduct port configured to receive a byproduct stream containing at least a substantial portion of the other gases; at least one foil microporous screen assembly disposed between and secured to the first and second end frames, the at least one foil microporous screen assembly comprising: At least one hydrogen selective membrane having a feed side and a permeate side, the permeate stream being formed at least in part by a portion of the mixed gas stream passing from the feed side to the permeate side, wherein the remaining portion of the mixed gas stream on the feed side forms at least in part the by-product stream, and at least one microporous screen structure comprising a non-porous planar sheet having a plurality of pores forming a plurality of fluid passages, each of the plurality of pores having a length defining a longitudinal axis, the plurality of pores being positioned in a plurality of rows on the non-porous planar sheet such that the longitudinal axes of the plurality of pores in each of the plurality of rows are (1) aligned with each other. This is parallel and (2) not parallel to the longitudinal axes of the pores in an adjacent row of the plurality of rows, the non-porous planar sheet includes substantially opposing planar surfaces configured to provide support for the permeate side, the plurality of fluid passages extending between the opposing surfaces, wherein the at least one hydrogen selective membrane is metallurgically bonded to the at least one microporous screen structure; and a plurality of frames disposed between the first end frame and the second end frame and the at least one foil microporous screen assembly and secured to the first end frame and the second end frame, each of the plurality of frames including a peripheral shell defining an open area.

FIG1 shows an example of a hydrogen generation assembly 20. Unless specifically excluded, the hydrogen generation assembly 20 may include one or more components of other hydrogen generation assemblies described herein. The hydrogen generation assembly may include any suitable structure configured to generate a product hydrogen stream 21. For example, the hydrogen generation assembly may include a feedstock delivery system 22 and a fuel processing assembly 24. The feedstock delivery system may include any suitable structure configured to selectively deliver at least one feed stream 26 to the fuel processing assembly.

In some embodiments, the feedstock delivery system 22 may further include any suitable structure configured to selectively deliver at least one fuel stream 28 to a burner or other heating assembly of the fuel processing assembly 24. In some embodiments, the feedstock stream 26 and the fuel stream 28 may be the same stream delivered to different portions of the fuel processing assembly. The feedstock delivery system may include any suitable delivery mechanism, such as a positive displacement or other suitable pump or mechanism for propelling the fluid stream. In some embodiments, the feedstock delivery system may be configured to deliver the feedstock stream 26 and/or the fuel stream 28 without the use of a pump and/or other electric fluid delivery mechanism. Examples of suitable feedstock delivery systems that can be used with the hydrogen generation assembly 20 include those 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 patents and patent applications are hereby incorporated by reference for all purposes.

The feed stream 26 may include at least one hydrogen-producing fluid 30, which may include one or more fluids that can act as reactants to produce the product hydrogen stream 21. For example, the hydrogen-producing fluid may include a carbonaceous feedstock, such as at least one alkane and/or alcohol. Examples of suitable alkane include methane, propane, natural gas, diesel, kerosene, gasoline, etc. Examples of suitable alcohols include methanol, alcohols, polyols (such as ethylene glycol and propylene glycol), etc. In addition, the hydrogen-producing fluid 30 may include water, such as when the fuel processing assembly produces the product hydrogen stream through steam reforming and/or spontaneous thermal reforming. When the fuel processing assembly 24 produces the product hydrogen stream through pyrolysis or catalytic partial oxidation, the feed stream 26 does not contain water.

In some embodiments, the feedstock delivery system 22 can be configured to deliver a hydrogen production fluid 30 comprising a mixture of water and a water-miscible carbonaceous feedstock (e.g., methanol and/or another water-soluble alcohol). The ratio of water to carbonaceous feedstock in such a fluid stream can vary depending on one or more of the following factors: the specific carbonaceous feedstock being used, user preferences, the design of the fuel processing assembly, the mechanisms used by the fuel processing assembly to generate the product hydrogen stream, etc. For example, the molar ratio of water to carbon can be approximately 1:1 to 3:1. Alternatively, a mixture of water and methanol can be delivered at a molar ratio of 1:1 or near 1:1 (37 wt. % water, 63 wt. % methanol), while mixtures of hydrocarbons or other alcohols can be delivered at a molar ratio of water to carbon greater than 1:1.

When the fuel processing assembly 24 produces a product hydrogen stream 21 through reforming, the feed stream 26 may comprise, for example, approximately 25 to 75 volume percent methanol or ethanol (or another suitable water-miscible carbonaceous feedstock) and approximately 25 to 75 volume percent water. For feed streams comprising at least substantially methanol and water, such streams may comprise approximately 50 to 75 volume percent methanol and approximately 25 to 50 volume percent water. Streams containing ethanol or other water-miscible alcohols may contain approximately 25 to 60 volume percent alcohol and approximately 40 to 75 volume percent water. An example feed stream for a hydrogen generation assembly 20 utilizing steam reforming or spontaneous thermal reforming contains 69 volume percent methanol and 31 volume percent water.

Although feedstock delivery system 22 is shown as being configured to deliver a single feed stream 26, the feedstock delivery system can be configured to deliver two or more feed streams 26. These streams can contain the same or different feedstocks and can have different compositions (at least one common component, an uncommon component) or the same composition. For example, a first feed stream can include a first component, such as a carbonaceous feedstock, and a second feed stream can include a second component, such as water. Additionally, although feedstock delivery system 22 can be configured to deliver a single fuel stream 28 in some embodiments, the feedstock delivery system can be configured to deliver two or more fuel streams. The fuel streams can have different compositions (at least one common component, an uncommon component) or the same composition. Additionally, the feed stream and fuel stream may be discharged from the feedstock delivery system at different stages. For example, one of these streams may be a liquid stream, while the other may be a gas stream. In some embodiments, both streams may be liquid streams, while in other embodiments, both streams may be gas streams. Furthermore, while the hydrogen generation assembly 20 is shown as including a single feedstock delivery system 22, the hydrogen generation assembly may include two or more feedstock delivery systems 22.

The fuel processing assembly 24 may include a hydrogen generation zone 32 configured to generate an output stream 34 containing hydrogen via any suitable hydrogen generation mechanism. The output stream may include hydrogen as at least a majority component and may include additional gaseous components. The output stream 34 may therefore be referred to as a "mixed gas stream" containing hydrogen as its majority component but including other gases.

The hydrogen generation zone 32 may include any suitable catalyst-containing bed or zone. When the hydrogen generation mechanism is steam reforming, the hydrogen generation zone may include a suitable steam reforming catalyst 36 to facilitate the production of an output stream 34 from the feed stream 26 comprising the carbonaceous feedstock and water. In such embodiments, the fuel processing assembly 24 may be referred to as a "steam reformer," the hydrogen generation zone 32 may be referred to as a "reforming region," and the 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 carbonaceous feedstock.

When the hydrogen generation mechanism is spontaneous thermal recombination, the hydrogen generation zone 32 may include a suitable spontaneous thermal recombination catalyst to promote the production of an output stream 34 from the feed stream 26 containing water and a carbonaceous feedstock in the presence of air. Additionally, the fuel processing assembly 24 may include an air delivery assembly 38 configured to deliver an air stream to the hydrogen generation zone.

In some embodiments, the fuel processing assembly 24 may include a purification (or separation) section 40, which may include any suitable structure configured to generate at least one hydrogen-enriched gas stream 42 from the output (or mixed gas) stream 34. The hydrogen-enriched gas stream 42 may include a greater hydrogen concentration than the output stream 34 and/or a lower concentration of one or more other gases (or impurities) present in the output stream. The product hydrogen stream 21 includes at least a portion of the hydrogen-enriched gas stream 42. Thus, the product hydrogen stream 21 and the hydrogen-enriched gas stream 42 may be the same stream and have the same composition and flow rate. Alternatively, some of the purified hydrogen in the hydrogen-rich gas stream 42 may be stored, for example, in a suitable hydrogen storage assembly for subsequent use and/or consumed by a fuel processing assembly. The purification section 40 may also be referred to as a "hydrogen purification device" or a "hydrogen processing assembly."

In some embodiments, the purification zone 40 can produce at least one by-product stream 44, which can be free of hydrogen or contain some hydrogen. The by-product stream can be discharged, transferred to a burner assembly and/or other combustion source, used as a heated fluid stream, stored for subsequent use, and/or otherwise utilized, stored, and/or disposed of. In addition, the purification zone 40 can emit the by-product stream as a continuous stream in response to delivery of the output stream 34, or can emit the stream intermittently, such as in a batch process or when the by-product portion of the output stream is at least temporarily retained in the purification zone.

The fuel processing assembly 24 may include one or more purification zones configured to produce one or more byproduct streams containing sufficient hydrogen to be suitable for use as a fuel stream (or feed stream) for a heating assembly of the fuel processing assembly. In some embodiments, the byproduct streams may have a sufficient flammability or hydrogen content to enable the heating assembly to maintain the hydrogen generation zone at a desired operating temperature or within a selected temperature range. For example, the byproduct streams may include hydrogen at 10 to 30% hydrogen by volume, 15 to 25% hydrogen by volume, 20 to 30% hydrogen by volume, at least 10 or 15% hydrogen by volume, at least 20% hydrogen by volume, etc.

The purification zone 40 may include any suitable structure configured to enrich (and/or increase) the concentration of at least one component of the output stream 21. In most applications, the hydrogen-enriched gas stream 42 will have a greater hydrogen concentration than the output stream (or mixed gas stream) 34. The hydrogen-enriched gas stream may also have a reduced concentration of one or more non-hydrogen components present in the output stream 34, wherein the hydrogen concentration of the hydrogen-enriched gas stream is greater than, the same as, or less than the hydrogen concentration of the output stream. For example, in conventional fuel cell systems, carbon monoxide, if present even at a few parts per million, can damage the fuel cell stack, whereas other non-hydrogen components such as water that may be present in the output stream 34 will not damage the stack, even at much greater concentrations. Thus, in such applications, the purification zone may not increase the overall hydrogen concentration, but will reduce the concentration of one or more non-hydrogen components that are harmful or potentially harmful to the desired application of the product hydrogen stream.

Examples of suitable devices for the purification zone 40 include one or more hydrogen-selective membranes 46, a chemical carbon monoxide removal assembly 48, and/or a pressure swing adsorption (PSA) system 50. The purification zone 40 may include more than one type of purification device, and the devices may have the same or different structures and/or be operated by the same or different mechanisms. The fuel processing assembly 24 may include at least one restrictive orifice and/or other flow restrictor downstream of the purification zone, such as a restrictive orifice and/or other flow restrictor associated with one or more product hydrogen streams, a hydrogen-enriched gas stream, and/or a by-product stream.

The hydrogen-selective membrane 46 can be permeable to hydrogen but at least substantially, if not completely, impermeable to other components of the output stream 34. The membrane 46 can be formed of any hydrogen-permeable material suitable for the operating environment and parameters of the purification zone 40. Examples of suitable materials for the membrane 46 include palladium and palladium alloys, and in particular thin films of such metals and metal alloys. Palladium alloys have proven particularly effective, particularly palladium having 35% to 45% by weight copper. Palladium-copper alloys containing approximately 40% by weight copper have proven particularly effective, but other relative concentrations and compositions may be used. Three other particularly effective alloys are palladium with 2 to 20 wt% gold, particularly palladium with 5 wt% gold; palladium with 3 to 10 wt% indium plus 0 to 10 wt% ruthenium, particularly palladium with 6 wt% indium plus 0.5 wt% ruthenium; and palladium with 20 to 30 wt% silver. When palladium and palladium alloys are used, the hydrogen-selective membrane 46 is sometimes referred to as a "foil." Typical thicknesses of hydrogen-permeable metal foils are less than 25 micrometers, preferably less than or equal to 15 micrometers, and most preferably between 5 and 12 micrometers. The foil can be any suitable size, such as 110 mm by 270 mm.

Chemical carbon monoxide removal assembly 48 is a device that chemically reacts carbon monoxide and/or other undesirable components in output stream 34 to form other potentially harmless components. Examples of chemical carbon monoxide removal assemblies 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) into carbon dioxide; and a methanation reactor configured to convert carbon monoxide and hydrogen into methane and water. Fuel processing assembly 24 may include more than one type and/or more than one chemical removal assembly 48.

Pressure swing adsorption (PSA) is a chemical process that removes gaseous impurities from the output stream 34 based on the principle that certain gases, under appropriate temperature and pressure conditions, are more strongly adsorbed onto an adsorbent material than others. Typically, non-hydrogen impurities are adsorbed and removed from the output stream 34. Adsorption of the impurity gas occurs under high pressure. As the pressure is reduced, the impurities are desorbed from the adsorbent material, thereby regenerating the adsorbent material. PSA is typically a cyclic process and requires at least two beds for continuous (as opposed to batch) operation. Examples of suitable adsorbent materials that can be used in the adsorption beds are activated carbon and zeolites. The PSA system 50 also provides an example of an apparatus for use in the purification zone 40 in which byproducts or removed components are not discharged from the zone as a gas stream concurrently with the purification of the output stream. Rather, these byproduct components are removed when the adsorbent material is regenerated or otherwise removed from the purification zone.

In Figure 1, the purge zone 40 is shown within the fuel processing assembly 24. The purge zone may alternatively be located separately downstream of the fuel processing assembly, as schematically illustrated by the dotted lines in Figure 1. The purge zone 40 may also include portions both internal and external to the fuel processing assembly.

The fuel processing assembly 24 may also include a temperature conditioning assembly in the form of a heating assembly 52. The heating assembly may be configured to generate at least one heated exhaust stream (or combustion stream) 54 from at least one heated fuel stream 28, typically when combusted in the presence of air. The heated exhaust stream 54 is schematically illustrated in FIG1 as a heated hydrogen generation zone 32. The heating assembly 52 may include any suitable structure configured to generate a heated exhaust stream, such as a burner or combustion catalyst that combusts a fuel with air to generate the heated exhaust stream. The heating assembly 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, indicator 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 assembly, the heating assembly 52 may be configured to receive at least one fuel stream 28 and combust the fuel stream in the presence of air to provide a hot combustion stream 54 that can be used to heat at least a hydrogen generation zone of the fuel processing assembly. Air can be delivered to the heating assembly via various mechanisms. For example, the air stream 62 can be delivered to the heating assembly as a separate stream, as shown in FIG1 . Alternatively or in addition, the air stream 62 can be delivered to the heating assembly along with at least one of the fuel streams 28 of the heating assembly 52 and/or drawn from the environment in which the heating assembly is utilized.

Additionally or alternatively, the combustion stream 54 may be used to heat other portions of the fuel processing assembly and/or fuel cell system that utilize the heating assembly. Additionally, other configurations and types of heating assemblies 52 may be used. For example, the heating assembly 52 may be an electric heating assembly that is configured to heat at least the hydrogen generation region 32 of the fuel processing assembly 24 by generating heat using at least one heating element, such as a resistive heating element. In such specific examples, the heating assembly 52 may not receive and combust a combustible fuel stream to heat the hydrogen generation region to a suitable hydrogen generation temperature. Examples of heating assemblies are disclosed in U.S. Patent No. 7,632,322, the entire disclosure of which is hereby incorporated herein by reference for all purposes.

The heating assembly 52 can be housed within a conventional housing or enclosure having a hydrogen generation zone and/or a separate zone (as discussed further below). The heating assembly can be positioned separately from the hydrogen generation zone 32 but in thermal and/or fluid communication therewith to provide the necessary heating of at least the hydrogen generation zone. The heating assembly 52 can be partially or completely within the conventional housing, and/or at least a portion (or all) of the heating assembly can be located outside the housing. When the heating assembly is located outside the housing, hot combustion gases from the burner assembly 60 can be delivered to one or more components within the housing via appropriate heat transfer conduits.

The heating assembly may also be configured to heat the feedstock delivery system 22, the feedstock supply stream, the hydrogen generation zone 32, the purification (or separation) zone 40, or any suitable combination of such systems, streams, and zones. Heating of the feedstock supply stream may include evaporating a liquid reactant stream or component of a hydrogen generation fluid used to generate hydrogen in the hydrogen generation zone. In that specific example, the fuel processing assembly 24 may be described as including a vaporization zone 64. The heating assembly may additionally be configured to heat other components of the hydrogen generation assembly. For example, the heated exhaust stream may be configured to heat a pressure vessel and/or other tank containing heated fuel and/or hydrogen generation fluid that forms at least some portion of the feed stream 26 and the fuel stream 28.

The heating assembly 52 can achieve and/or maintain any suitable temperature in the hydrogen production zone 32. Steam reformers typically operate at temperatures in the range of 200°C and 900°C. However, temperatures outside this range are within the scope of the present invention. When the carbon-containing feedstock is methanol, the steam reforming reaction will typically operate in a temperature range of about 200°C to 500°C. Examples of such ranges include 350 to 450°C, 375 to 425°C, and 375 to 400°C. When the carbon-containing feedstock is hydrocarbons, ethanol, or another alcohol, a temperature range of about 400 to 900°C will typically be used for the steam reforming reaction. Exemplary subsets of this range include 750-850°C, 725-825°C, 650-750°C, 700-800°C, 700-900°C, 500-800°C, 400-600°C, and 600-800°C. The hydrogen production zone 32 may include two or more regions or sections, each of which may operate at the same or different temperatures. For example, when the hydrogen producing fluid includes hydrocarbons, the hydrogen production zone 32 may include two different hydrogen production sections or zones, one of which operates at a lower temperature than the other to provide a pre-reforming zone. In these specific examples, the fuel processing assembly may also be referred to as including two or more hydrogen production zones.

Fuel stream 28 can include any flammable liquid and/or gas suitable for consumption by heating assembly 52 to provide the desired heat output. Some fuel streams can be gases when delivered and combusted by heating assembly 52, while other fuel streams can be delivered to the heating assembly as liquid streams. 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. Additional examples include low molecular weight 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 the hydrogen generation assembly 20 that include a temperature-modulating assembly in the form of a cooling assembly rather than a heating assembly (such as may be used when an exothermic hydrogen generation process, such as partial oxidation, is utilized rather than an endothermic process, such as steam reforming), the feedstock delivery system may be configured to supply a fuel or coolant stream to the assembly. Any suitable fuel or coolant fluid may be used.

The fuel processing assembly 24 may further include a shell or housing 66 containing at least the hydrogen generation zone 32, as shown in FIG1 . In some embodiments, the vaporization zone 64 and/or the purge zone 40 may also be contained within the shell. The shell 66 may enable the components of the steam reformer or other fuel processing mechanism to be moved as a unit. The shell may also protect the components of the fuel processing assembly from damage by providing a protective enclosure and/or may reduce the heating requirements of the fuel processing assembly because the components can be heated as a unit. The shell 66 may include an insulating material 68, such as a solid insulating material, a blanket insulating material, and/or an air-filled cavity. The insulating material may be inside the shell, outside the shell, or both. When the insulating material is outside the shell, the fuel processing assembly 24 may further include an outer cover or jacket 70 outside the insulating material, as schematically illustrated in FIG1 . The fuel processing assembly may include different shells that include additional components of the fuel processing assembly, such as the feedstock delivery system 22 and/or other components.

One or more components of the fuel processing assembly 24 may extend beyond the housing or be located externally of the housing. For example, the purge zone 40 may be located externally of the housing 66, e.g., spaced apart from the housing but in fluid communication with it via suitable fluid transfer conduits. As another example, a portion of the hydrogen generation zone 32 (e.g., a portion of one or more reforming catalyst beds) may extend beyond the housing, as schematically indicated in FIG1 by the dashed lines representing an alternative housing configuration. Examples of suitable hydrogen generation assemblies and components thereof are disclosed in U.S. Patent Nos. 5,861,137, 5,997,594, and 6,221,117, the entire disclosures of which are hereby incorporated by reference for all purposes.

Another example of a hydrogen generation assembly 20 is shown in FIG2 and generally designated 72. Unless specifically excluded, the hydrogen generation assembly 72 may include one or more components of the hydrogen generation assembly 20. The hydrogen generation assembly 72 may include a feedstock delivery system 74, a vaporization region 76, a hydrogen generation region 78, and a heating assembly 80, as shown in FIG2 . In some embodiments, the hydrogen generation assembly 20 may also include a purification region 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 generation assembly. For example, the feedstock delivery system may include a feedstock tank (or container) 84 and a pump 86. The feedstock tank may contain any suitable hydrogen generation fluid 88, such as water and a carbonaceous feedstock (e.g., a methanol/water mixture). The pump 86 may have any suitable structure configured to deliver the hydrogen generation fluid, which may be in the form of a feed stream 90 containing at least one liquid, including water and a carbonaceous feedstock, to the vaporization zone 76 and/or the hydrogen generation zone 78.

The vaporization region 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 region 76 can include a vaporizer 92 configured to convert at least a portion of the liquid-containing feed stream 90 into one or more vapor-phase feed streams 94. In some embodiments, the vapor-phase feed stream can include a liquid. An example of a suitable vaporizer is a coil vaporizer, such as a stainless steel coil.

The hydrogen generation zone 78 may include any suitable structure configured to receive one or more feed streams (such as a gaseous feed stream 94 from a vaporization zone) to produce one or more output streams 96 containing hydrogen as a major component and other gases. The hydrogen generation zone may generate the output streams via any suitable mechanism. For example, the hydrogen generation zone 78 may generate the output stream 96 via a steam reforming reaction. In such an example, the hydrogen generation zone 78 may include a steam reforming zone 97 having a reforming catalyst 98 configured to promote and/or facilitate the steam reforming reaction. When the hydrogen generation zone 78 generates the output stream 96 via a steam reforming reaction, the hydrogen generation assembly 72 may be referred to as a "steam reforming hydrogen generation assembly" and the output stream 96 may be referred to as a "reformate stream."

The heating assembly 80 can include any suitable structure configured to generate at least one heated exhaust stream 99 for heating one or more other components of the hydrogen generation assembly 72. For example, the heating assembly 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 a liquid-containing feed stream is vaporized to form a vapor-phase feed stream. Additionally or alternatively, the heating assembly 80 can heat the hydrogen generation zone to any suitable temperature, such as at least a minimum hydrogen generation temperature or a temperature at which at least a portion of the vapor-phase feed stream is reacted to produce hydrogen to form an output stream. The heating assembly can be in thermal communication with one or more components of the hydrogen generation assembly, such as the vaporization zone and/or the hydrogen generation zone.

The heating assembly may include a burner assembly 100, at least one blower 102, and an igniter assembly 104, as shown in FIG2 . The burner assembly may include any suitable structure configured to receive at least one air stream 106 and at least one fuel stream 108 and 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 generation assembly. The blower 102 may include any suitable structure configured to generate the air stream 106. The igniter assembly 104 may include any suitable structure configured to ignite the fuel stream 108.

The purification section 82 may include any suitable structure configured to produce at least one hydrogen-enriched gas stream 112, which may include a greater hydrogen concentration than the output stream 96 and/or a reduced concentration of one or more other gases (or impurities) present in the output stream. The purification section may produce at least one byproduct stream or fuel stream 108, which may be sent to the combustor assembly 100 and used as the fuel stream for the combustor assembly, as shown in FIG2 . The purification section 82 may include a flow restriction orifice 111, a filter assembly 114, a membrane assembly 116, and a methanation reactor assembly 118. A filter assembly, such as one or more hot gas filters, may be configured to remove impurities from the output stream 96 prior to the hydrogen purification membrane assembly.

The membrane assembly 116 can include any suitable structure configured to receive the output or mixed gas stream 96 containing hydrogen and other gases and produce a permeate or hydrogen-enriched gas stream 112 containing a greater concentration of hydrogen and/or a lower concentration of other gases than the mixed gas stream. The membrane assembly 116 can incorporate planar or tubular hydrogen-permeable (or hydrogen-selective) membranes, and more than one type of hydrogen-permeable membrane can be incorporated into the membrane assembly 116. The permeate stream can be used for any suitable application, such as in one or more fuel cells. In some embodiments, the membrane assembly can produce a byproduct or fuel stream 108 that includes at least a substantial portion of the other gases. Methanation reactor assembly 118 may include any suitable structure configured to convert carbon monoxide and hydrogen into methane and water. Although purification zone 82 is shown as including flow restriction orifice 111, filter assembly 114, membrane assembly 116, and methanation reactor assembly 118, the purification zone may have fewer components than all of these assemblies and/or may alternatively or additionally include one or more other components configured to purify output stream 96. For example, purification zone 82 may include only membrane assembly 116.

In some embodiments, the hydrogen generation assembly 72 can include a shell or housing 120 that can at least partially contain one or more other components of the assembly. For example, the shell 120 can at least partially contain the vaporization region 76, the hydrogen generation region 78, the heating assembly 80, and/or the purge region 82, as shown in FIG2 . The shell 120 can include one or more exhaust vents 122 configured to discharge at least one combustion exhaust stream 124 generated by the heating assembly 80.

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

In some embodiments, the hydrogen generation assembly 72 may include a heat exchange assembly 136, which may include one or more heat exchangers 138 configured to transfer heat from one portion of the hydrogen generation assembly to another portion. For example, the heat exchange assembly 136 may transfer heat from the hydrogen-enriched gas stream 112 to the feed stream 90, thereby raising the temperature of the feed stream before entering the vaporization zone 76, and cooling the hydrogen-enriched gas stream 112.

An example of the purification zone 40 (or hydrogen purification device) of the hydrogen generation assembly 20 of FIG. 1 is generally indicated at 144 in FIG. 3 .

Unless specifically excluded, the hydrogen purification device may include one or more components of the other purification zones described herein. The hydrogen purification device 40 may include a hydrogen separation zone 146 and a housing 148. The housing may define an interior volume 150 having an interior perimeter 152. The housing 148 may include at least a first portion 154 and a second portion 156 coupled together to form a body 149 in the form of a sealed pressure vessel that may include defined input and output ports. The ports may define flow paths through which gases and other fluids are delivered to and removed from the interior volume of the housing.

The first portion 154 and the second portion 156 can be coupled together using any suitable retaining mechanism or structure 158. Examples of suitable retaining structures include welds and/or screws. Examples of seals that can be used to provide a fluid-tight interface between the first and second portions include gaskets and/or welds. Additionally or alternatively, the first portion 154 and the second portion 156 can be secured together such that at least a predetermined amount of compression is applied to various components defining a hydrogen separation zone that can be incorporated into a housing and/or other components of the hydrogen generation assembly. The applied compression ensures that the various components remain properly positioned within the housing. Additionally or alternatively, compression applied to the various components defining the hydrogen separation region and/or other components may provide a fluid-tight interface between the various components defining the hydrogen separation region, between the various other components, and/or between the components defining the hydrogen separation region and the other components.

The housing 148 may include a mixed gas zone 160 and a permeate zone 162, as shown in FIG3 . The mixed gas zone and the permeate zone may be separated by a hydrogen separation zone 146 . At least one input port 164 may be provided through which a fluid stream 166 is delivered to the housing. The fluid stream 166 may be a mixed gas stream 168 containing hydrogen 170 and other gases 172 delivered to the mixed gas zone 160 . Hydrogen may be a majority component of the mixed gas stream. The hydrogen separation zone 146 may extend between the mixed gas zone 160 and the permeate zone 162 such that gas in the mixed gas zone must pass through the hydrogen separation zone in order to enter the permeate zone. For example, the gas may be required to pass through at least one hydrogen selective membrane as discussed further below. The permeate zone and the mixed gas zone may have any suitable relative sizes within the housing.

The housing 148 may also include at least one product outlet 174 through which a permeate stream 176 may be received and removed from the permeate zone 162. The permeate stream may contain a greater concentration of hydrogen and a lower concentration of at least one of the other gases than the mixed gas stream. In some embodiments, the permeate stream 176 may at least initially include a carrier gas component or a residual gas component, such as may be delivered as a residual gas stream 178 via a residual gas vent 180 in fluid communication with the permeate zone. The housing may also include at least one byproduct outlet 182 through which a byproduct stream 184 containing at least one of a substantial portion of the other gas 172 and a reduced concentration of hydrogen 170 (relative to the mixed gas stream) is removed from the mixed gas region.

The hydrogen separation zone 146 can 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 surface 188. The mixed gas stream 168 can be delivered to the mixed gas zone of the housing so that the mixed gas stream contacts the mixed-gas surfaces of the one or more hydrogen-selective membranes. A permeate stream 176 can be formed from at least a portion of the mixed gas stream that passes through the hydrogen separation zone to the permeate zone 162. A 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, the byproduct stream 184 can contain a portion of the hydrogen present in the mixed gas stream. The hydrogen separation zone may also be configured to intercept or otherwise retain at least a portion of the other gases, which may then be removed as a by-product stream as the separation zone is replaced, regenerated, or otherwise recharged.

In Figure 3, streams 166, 176, 178, and/or 184 may include more than one actual stream flowing into or out of the hydrogen purification device 144. For example, the hydrogen purification device may receive a plurality of mixed gas streams 168, a single mixed gas stream 168 that is split into two or more streams before contacting the hydrogen separation zone 146, a single stream that is delivered to the internal volume 150, etc. Thus, the housing 148 may include more than one input port 164, product output port 174, residual gas port 180, and/or by-product output port 182.

The hydrogen-selective membrane can be formed from any hydrogen-permeable material suitable for the operating environment and parameters used in operating the hydrogen purification device. Examples of hydrogen purification devices are disclosed in U.S. Patent Nos. 5,997,594 and 6,537,352, the entire disclosures of which are hereby incorporated by reference for all purposes. In some embodiments, the hydrogen-selective membrane can be formed from at least one of palladium and a palladium alloy. Examples of palladium alloys include alloys of palladium with copper, silver, and/or gold. Examples of various membranes, membrane configurations, and methods for preparing membranes and membrane configurations are disclosed in U.S. Patent Nos. 6,152,995, 6,221,117, 6,319,306, and 6,537,352, the entire disclosures of which are hereby incorporated by reference for all purposes.

In some embodiments, a plurality of spaced-apart hydrogen-selective membranes 186 may be used in the hydrogen separation region to form at least a portion of a hydrogen separation assembly 192. When present, the plurality of membranes may collectively define one or more membrane assemblies 194. In such embodiments, the hydrogen separation assembly may generally extend from the first portion 154 to the second portion 156. Thus, the first and second portions may effectively compress the hydrogen separation assembly. In some embodiments, the housing 148 may additionally or alternatively include end plates (or end frames) coupled to opposing sides of the main body portion. In such embodiments, the end plates may effectively compress the hydrogen separation assembly (and other components that may be housed within the housing) between the 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 passed into contact with the mixed gas surface of the membrane at a pressure higher than the gas in the permeate zone of the hydrogen separation zone. In some embodiments, when the hydrogen separation zone is used to separate the mixed gas stream into a permeate stream and a by-product stream, the hydrogen separation zone can be heated to a high temperature by any suitable mechanism. Examples of suitable operating temperatures for hydrogen purification using palladium and palladium alloy membranes include temperatures of at least 275°C, temperatures of at least 325°C, temperatures of at least 350°C, temperatures in the range of 275 to 500°C, temperatures in the range of 275 to 375°C, temperatures in the range of 300 to 450°C, temperatures in the range of 350 to 450°C, etc.

An example of a hydrogen purification device 144 is generally indicated at 196 in FIG. 4 . Unless specifically excluded, the hydrogen purification device 196 may include one or more components and/or purification zones of other hydrogen purification devices described herein. The hydrogen purification device 196 may include a shell or housing 198, which may include a first end plate or end frame 200 and a second end plate or end frame 202. The first and second end plates may be configured to be fastened and/or compressed together to define a sealed pressure vessel having an interior compartment 204 in which a hydrogen separation zone is supported. Similar to the hydrogen purification device 144 , the first end plate and the second end plate may include an input port, an output port, a residual gas port, and a by-product port (not shown).

The hydrogen purification device 196 may also include at least one foil microporous screen assembly 205, which may be positioned between and/or secured to the first and second end plates. The foil microporous screen assembly may include at least one hydrogen selective membrane 206 and at least one microporous screen structure 208, as shown in FIG5 . The hydrogen selective membrane may be configured to receive at least a portion of a mixed gas stream from an 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 by the portion of the mixed gas stream passing from the feed side to the permeate side, wherein the remaining portion of the mixed gas stream on the feed side forms at least a portion of the by-product stream.

One or more of the hydrogen-selective membranes can be metallurgically bonded to the microporous screen structure 208. For example, the permeate side of the hydrogen-selective membrane can be metallurgically bonded to the microporous screen structure. In some embodiments, one or more of the hydrogen-selective membranes 206 (and/or the permeate sides of such membranes) can be diffusion bonded to the microporous screen structure to form a solid diffusion bond between the membrane and the microporous screen structure. For example, the permeate side of the membrane and the microporous screen structure can be in contact with each other and exposed to high temperature and/or high pressure to allow the surfaces of the membrane and the microporous screen structure to interpenetrate each other over time.

In some embodiments, the microporous mesh structure may be coated with a thin metal layer or intermediate bonding layer to assist diffusion bonding. For example, a thin coating of nickel, copper, silver, gold, or other metal undergoes solid state diffusion bonding but does not (1) melt at or below 700°C and enter the liquid phase and (2) form a low melting alloy at or below 700°C after diffusion into the hydrogen selective membrane. The thin metal layer can be applied to the microporous screen structure by a suitable deposition process (e.g., electrochemical plating, vapor deposition, sputtering, etc.) through a thin coating of an intermediate bonding layer on the surface of the microporous screen structure that will contact the hydrogen-selective membrane. In some embodiments, the foil microporous screen assembly 205 includes only the hydrogen-selective membrane and the microporous screen structure (with or without a coating thereon) and does not have any other frame, gasket, component, and/or structure attached, bonded, and/or metallurgically bonded to either or both of the hydrogen-selective membrane and/or the microporous screen structure. In other embodiments, the hydrogen-selective membrane may be secured to at least one membrane frame (not shown), which may in turn be secured to the first end frame and the second end frame.

The microporous screen structure 208 may comprise any suitable structure configured to support at least one hydrogen-selective membrane. For example, the microporous screen structure may comprise a non-porous planar sheet 213 having generally opposing surfaces 214 and 215 configured to provide support for a permeate side 212, and a plurality of pores 216 forming a plurality of fluid passages 217 extending between the opposing surfaces, the fluid passages allowing permeate to flow through the microporous screen structure, as shown in FIG6 . The pores may be formed in the non-porous planar sheet by electrochemical etching, laser drilling, and other mechanical forming processes such as stamping or die cutting. In other words, the planar sheet is made of one or more materials that do not include any openings or pores, and the only pores or openings in the sheet are added via one or more of the above methods. In some embodiments, one or more of the pores (or all of the pores) can be formed in the non-porous planar sheet such that their longitudinal axes, or the longitudinal axes of the fluid passageways, are perpendicular to the plane of the non-porous planar sheet, as shown in FIG6 . The non-porous planar sheet can be of any suitable thickness, such as a thickness between 100 microns and approximately 200 microns.

In some embodiments, the microporous screen structure 208 can include one or more perforated regions (or portions) 218 that include a plurality of apertures, and one or more non-perforated regions (or portions) 219 that do not include (or exclude) a plurality of apertures. Although only a few apertures 216 are illustrated in FIG. 6 , the apertures 216 are distributed across the entire length and width of the perforated portion. The perforated regions can be discrete or separated from one or more other perforated regions. The non-perforated regions 219 can include a peripheral region (or portion) 220 that frames one or more of the perforated regions and/or one or more boundary regions (or portions) 221 that separate or define more than two discrete portions of the perforated region. In other words, each perforated portion may be separated from other adjacent discrete perforated portions by at least one boundary portion that does not contain a plurality of pores.

The apertures 216 can include any suitable pattern, shape, and/or size. In some embodiments, the apertures can be formed with one or more patterns that maximize the combined aperture area while maintaining sufficient stiffness in the microporous screen structure to prevent excessive deflection under compressive loads. The apertures 216 can be circular (ring-shaped), as shown in FIG6 , or oblong, as shown in FIG7 through FIG10 , or racetrack or stadium-shaped, or oval, elliptical, hexagonal, triangular, square, rectangular, octagonal, and/or other suitable shapes. In some embodiments, the apertures 216 in the perforated area can be a single, fixed shape. In other embodiments, the apertures 216 in the perforated region can be any suitable combination of two or more different shapes, such as two or more of the above shapes.

The pores 216 can have any suitable orientation and/or be arranged in any suitable pattern. For example, FIG. 7 shows pores 216 oriented longitudinally (or along the length of the perforated region or planar sheet) and connected in parallel rows. In other words, each pore 216 has a length that defines a longitudinal axis 223, and the longitudinal axes of all pores in FIG. 7 are parallel and/or coaxial with the longitudinal axis 225 of the planar sheet 213 (shown in FIG. 6). Alternatively, FIG. 9-10 shows pores oriented laterally (or along the width of the perforated region or planar sheet). In other words, the longitudinal axes 223 of all pores in the examples of FIG. 9-10 are perpendicular to the longitudinal axis 225 of the planar sheet 213.

Although the pores 216 are arranged in the same direction or orientation in Figures 7 and 9-10, other embodiments of the planar sheet 213 may include pores 216 having two or more directions and/or orientations. For example, the pores 216 may be arranged in a staggered pattern such that the pores in each column or row are oriented differently (e.g., at 30, 45, 60, 90, or 120 degrees) than the pores in each adjacent column or row. In other words, the longitudinal axes 223 of the pores 216 in each column or row are parallel to each other and/or non-parallel to the longitudinal axes 223 of the pores in one or more adjacent columns or rows on the planar sheet 213. In one example, the apertures 216 are also oriented diagonally and connected in parallel rows such that each row of apertures is oriented approximately ninety degrees from an adjacent row of apertures, as shown in Figure 8. Alternatively or in addition, one or more apertures 216 in one or more rows and/or columns may be oriented differently than one or more other apertures in the same row and/or column.

The apertures can be of any suitable size. For example, when the apertures are circular, the diameter can range from about 0.003 inches to about 0.020 inches. Alternatively, when the apertures are oval or elliptical, the radius of the rounded end of the oval or elliptical can range from 0.001 inches to about 0.010 inches, and the length of the oval or elliptical can be up to ten times the radius. Furthermore, when the apertures are oblong or stadium-shaped, the width or diameter can range from 0.005 inches to 0.02 inches, and the length can range from 0.05 inches to more than ten times the diameter, such as 0.8 inches. Example pore sizes in FIG8 are: a diameter of 0.10 inches at the rounded end and a length of 0.028 inches (i.e., an aspect ratio of approximately 3), with a spacing of 0.006 inches between pores or 0.011 inches between the centers of adjacent pores. The pattern and example dimensions shown in FIG8 provide a total open area of approximately 50% in the microporous screen structure.

In some examples, one or more apertures 216 can be sized to span the entire or substantially the entire width or length of the perforated area. In the example shown in FIG9 , the stadium-shaped apertures are oriented transversely and span the entire or substantially the entire width of the perforated area or portion, such that the aspect ratio (length/width) is much greater than 10. Examples of aperture sizes in FIG9 are 0.005 to 0.02 inches in width and up to 8 inches in length. The apertures can be spaced about 0.006 inches apart (i.e., the width of the non-perforated portion or solid boss between adjacent apertures) to provide a total open area of up to about 62.5%.

In some examples, the pores 216 can have a combination of sizes. For example, the pores 216 can be sized so that the planar sheet 213 includes columns and/or rows of pores having: (1) a smaller number of pores having one or more longer lengths; and (2) a larger number of pores having one or more shorter lengths. In some examples, the columns and/or rows of smaller number of pores having longer lengths alternate with columns and/or rows of larger number of pores having shorter lengths, such as in a staggered pattern. In the example shown in FIG10 , the apertures 216 are oriented transversely (or perpendicular to the longitudinal axis 225 of the planar sheet 213), and each column and/or row alternates between two apertures having a longer length and three apertures having a shorter length. The lengths of the apertures in each column and/or row can be the same or different. Examples of the dimensions of the apertures in FIG10 are 0.005 to 0.02 inches in width and 0.05 to 8 inches in length. The apertures can be spaced about 0.006 inches apart (i.e., the width of the non-perforated portion or solid boss between adjacent apertures). Other combinations of patterns, sizes, orientations, and/or shapes of the apertures 216 are possible and encompassed by the present invention.

The non-porous planar sheet may comprise any suitable material. For example, the non-porous planar sheet may comprise stainless steel. The stainless steel may include 300 series stainless steel (e.g., 303 stainless steel (aluminum modified), 304 stainless steel, etc.), 400 series stainless steel, 17-7 PH, 14-8 PH, and/or 15-7 PH. In some embodiments, the stainless steel may include approximately 0.6 wt% to approximately 3.0 wt% aluminum. In some embodiments, the non-porous planar sheet may comprise carbon steel, copper or a copper alloy, aluminum or an aluminum alloy, nickel, a nickel-copper alloy, and/or a base metal electroplated with silver, nickel, and/or copper. The substrate metal may include one or more of the carbon steel or stainless steel mentioned above.

The hydrogen-selective membrane 206 can be configured to be larger than the perforated area or field of the microporous screen structure so that when the hydrogen-selective membrane is metallurgically bonded to the microporous screen structure, a peripheral portion 222 of the hydrogen-selective membrane contacts one or more non-perforated areas 219 of the microporous screen structure. In some embodiments, a single hydrogen-selective membrane can be metallurgically bonded to a single microporous screen structure, as shown in FIG5 . In other embodiments, two or more hydrogen-selective membranes 206 can be metallurgically bonded to a single microporous screen structure 208. For example, two, three, four, five, six, seven, eight, nine, ten, or more hydrogen-selective membranes 206 can be metallurgically bonded to a single microporous screen structure 208. Figures 11-12 show example foil microporous screen assemblies 205 having six hydrogen-selective membranes 206 metallurgically bonded to a single microporous screen structure 208. Figure 13 shows an example foil microporous screen assembly 205 having two hydrogen-selective membranes 206 metallurgically bonded to a single microporous screen structure 208, and Figure 14 shows an example foil microporous screen assembly 205 having four hydrogen-selective membranes 206 metallurgically bonded to a single microporous screen structure 208.

When two or more hydrogen-selective membranes 206 are metallurgically bonded to the microporous screen structure, the microporous screen structure can include two or more discrete perforated regions 218 separated by one or more non-perforated regions 219. In some embodiments, the perforated regions 218 can be sized the same as the other perforated regions 218. For example, FIG12 shows six discrete perforated regions 218 of approximately the same size. In other embodiments, one or more perforated regions 218 can be sized smaller and/or larger than the other perforated regions 218. The hydrogen-selective membrane 206 can be metallurgically bonded to each of the perforated regions, as shown in FIG11. Alternatively or additionally, the hydrogen-selective membrane can be metallurgically bonded to two or more discrete perforated regions 218. The hydrogen-selective membrane 206 can be sized such that when the membrane is metallurgically bonded to one or more perforated regions 218, a peripheral portion 222 of the membrane contacts one or more non-perforated regions 219.

The microporous screen structure 208 can be sized to be contained within (e.g., completely contained within) the open area of the permeate frame and/or supported by a membrane support structure within the open area, as shown in FIG5 . In other words, the microporous screen structure can be sized so that it does not contact the peripheral shell of the permeate frame when the microporous screen structure and the permeate frame are secured or compressed to the first and second end frames. Alternatively, the microporous screen structure can be supported by and/or secured to a non-porous peripheral wall portion or frame (not shown), such as the peripheral shell of the permeate frame. When the microporous screen structure is secured to the non-porous peripheral wall portion, the microporous screen structure may be referred to as a "porous central region portion." Other examples of microporous screen 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 device 196 may also include a plurality of plates or frames 224, which are disposed between and secured to the first end frame and/or the second frame. The frame may include 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 shell 226 and at least one first support member 228, as shown in FIG4 , and the peripheral shell may define an open area 230 and a frame plane 232. In addition, the peripheral shell 226 may include a first opposing side 234 and a second opposing side 236, as well as a third opposing side 238 and a fourth opposing side 240, as shown in FIG4 .

The first support member 228 can comprise any suitable structure configured to support the first portion 242 of the foil microporous screen assembly 205, as shown in FIG4 . For example, the first support members of the plurality of frames can be coplanar with each other (or coplanar with other first support members of other frames in the plurality of frames) within a first support plane 244 to support the first portion 242 of the hydrogen-selective membrane, as shown in FIG4 . In other words, the first support members of each frame in the plurality of frames can mirror the first support members of other frames in the plurality of frames. The first support members can have any suitable orientation relative to the frame plane 232. For example, the first support plane 244 can be perpendicular to the frame plane, as shown in FIG4 . Alternatively, the first membrane-supporting plane can intersect the frame plane 232 but not be perpendicular thereto.

In some embodiments, the frame 224 may include a second support member 246 and/or a third support member 248, which may include any suitable structure configured to support the second portion 250 and/or the third portion 252 of the foil microporous screen assembly 205, as shown in FIG4 . For example, the second support members of a plurality of frames may be coplanar with each other (or coplanar with other second support members of a plurality of frames) in a second support plane 254 to support the second portion 250 of the foil microporous screen assembly. Additionally, the third support members of a plurality of frames may be coplanar with each other (or coplanar with other third support members of a plurality of frames) in a third support plane 256 to support the third portion 252 of the foil microporous screen assembly. In other words, the second support member of each frame in the plurality of frames can mirror the second support member of the other frames in the plurality of frames, and the third support member of each frame in the plurality of frames can mirror the third support member of the other frames in the plurality of frames. The second support plane and/or the third support plane can have any suitable orientation relative to the frame plane 232. For example, the second support plane 254 and/or the third support plane 256 can be perpendicular to the frame plane, as shown in FIG4. Alternatively, the second support plane and/or the third support plane can intersect the frame plane 232 but not be perpendicular to the frame plane.

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

The first, second and/or third support members may, for example, be in the form of one or more protrusions or fingers 258 attached to and/or formed with the peripheral shell. The protrusions may extend from the peripheral shell in any suitable direction. The protrusions may be the full thickness of the peripheral shell, or may be less than the full thickness of the shell. The protrusions of each of the frames 224 may be compressed against the foil microporous screen assembly, thereby locking the assembly in place. In other words, the protrusions of the frames 224 may support the foil microporous screen assembly by being stacked extensions of the end frames within the first membrane support plane and/or the second membrane support plane. In some embodiments, the protrusion 258 can include one or more receptacles or apertures (not shown) configured to receive at least one fastener (not shown) to secure the frame 224 to the first end frame and/or the second end frame.

The frame 224 may include at least one feed frame 260, at least one permeate frame 262, and a plurality of sealing pads or sealing pad frames 264, as shown in FIG4 . The feed frame 260 may be positioned between one of the first end frame and the second end frame and at least one foil microporous screen assembly 205, or between two foil microporous screen assemblies 205. The feed frame may include a feed frame peripheral shell 266, a feed frame input conduit 268, a feed frame output conduit 270, a feed frame open area 272, and at least one first feed frame support member 274, as shown in FIG4 . In some embodiments, the feed frame may include a second feed frame support member 276 and/or a third feed frame support member 278. In some embodiments, the end plate, the foil microporous screen assembly, and the frame 224 are fastened or compressed together, such as mechanically fastened and/or mechanically compressed by screws and/or other fasteners, without any metallurgical bonds and/or other types of chemical bonds between two or more components of the hydrogen purification device (except for the metallurgical bonds described above between the hydrogen-selective membrane and the coated or uncoated microporous screen structure within the foil microporous screen assembly). For example, there are no sealing gaskets and/or frames metallurgically or otherwise chemically bonded to the hydrogen-selective membrane and/or microporous screen structure of the foil microporous screen assembly and all other components of the hydrogen purification device.

Another example of a hydrogen purification device 144 is generally indicated in Figure 15 at 396. Unless specifically excluded, the hydrogen purification device 396 may include one or more components and/or purification zones of other hydrogen purification devices described herein.

Hydrogen purification device 396 is similar in many respects to hydrogen purification device 196 but has a differently shaped frame, unsupported components, a differently sized foil microporous screen assembly, and fewer sealing gasket frames, as further described below. Components or portions of hydrogen purification device 396 correspond to components or portions of hydrogen purification device 196 and are labeled in FIG15 by similar figure numbers having the general form "3XX" instead of "1XX" and "4XX" instead of "2XX." Therefore, features 398, 400, 402, 404, 405, 406, 408, 424, 426, 434, 436, 438, 440, 460, 462, 464, etc. may be the same or substantially the same as their respective counterparts in hydrogen purification device 196, namely features 198, 200, 202, 204, 205, 206, 208, 224, 226, 234, 236, 238, 240, 260, 262, 264, etc.

The hydrogen purification device 396 may include a shell or housing 398, which may include a first end plate or end frame 400 and a second end plate or end frame 402. The first end plate and the second end plate may be configured to be fastened and/or compressed together to define a sealed pressure vessel having an interior compartment 404 in which the hydrogen separation zone is supported.

The hydrogen purification device 396 may also include at least one foil microporous screen assembly 405, which may be positioned between and/or secured to the first and second end plates. The foil microporous screen assembly may include at least one hydrogen-selective membrane 406 and at least one microporous screen structure 408. One or more of the hydrogen-selective membranes may be metallurgically bonded to the microporous screen structure 408. For example, one or more of the hydrogen-selective membranes 406 may be diffusion bonded to the microporous screen structure to form a solid diffusion bond between the membrane and the microporous screen structure. The foil microporous screen assembly 405 is sized to fit within the open area of the permeate frame and is therefore smaller in length and width than or relative to the foil microporous screen assembly 205 .

The hydrogen purification device 396 may also include a plurality of panels or frames 424 disposed between and secured to the first end frame and/or the second end frame. The frame 424 may include a peripheral shell 426. The peripheral shell may define an open area 430. Additionally, the peripheral shell 426 may include a first opposing side 434 and a second opposing side 436, as well as a third opposing side 438 and a fourth opposing side 440. Unlike the frame 224 of the hydrogen purification device 196, the frame 424 does not include any supporting components.

The frame 424 may include at least one feed frame 460, at least one permeate frame 462, and a plurality of seals or seal frames 464. The feed frame 460 may be positioned between one of the first end frame and the second end frame and at least one foil microporous screen assembly 405, or between two foil microporous screen assemblies 405. The feed frame may include components at least substantially similar to those of the feed frame 260, such as a feed frame peripheral shell, a feed frame input conduit, a feed frame output conduit, and/or a feed frame open area.

The permeate frame 462 can be positioned such that at least one foil microporous screen assembly is disposed between one of the first end frame and the second end frame and the permeate frame, or between two foil microporous screen assemblies. The permeate frame can include components at least substantially similar to those of the permeate frame 262, such as a permeate frame perimeter shell, a permeate frame output conduit, a permeate frame open area, and/or a membrane support structure.

Frame 424 may also include a sealing gasket or sealing gasket frame 464. The sealing gasket 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 400, 402 and the feed frame 460, and/or between the feed frame 460 and the foil microporous screen assembly 405. Unlike hydrogen purification device 196, hydrogen purification device 396 does not include a sealing gasket frame 464 between the foil microporous screen assembly and the permeate frame 462. Similar to hydrogen purification device 196, the width of the feed frame and the sealing gasket frame is greater than the width of the permeate frame (or the open area of the feed frame and the sealing gasket frame is smaller than the open area of the permeate frame), so that the excess width covers the edge of the foil microporous screen assembly to eliminate or minimize leakage from the feed side to the permeate side or from the permeate side to the feed side (for example, the excess width of the feed frame and the sealing gasket frame covers the edge of the foil microporous screen assembly). In some embodiments, the excess width corresponds to the width of the peripheral (non-perforated) portion of the microporous screen structure of the foil microporous screen assembly. Industry Applicability

The present disclosure, including hydrogen purification devices and components thereof, is applicable to fuel processing and other industries where hydrogen is purified, produced, and/or utilized.

The disclosures set forth above encompass a variety of unique inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and described herein are not to be considered in a limiting sense, as numerous variations are possible. The subject matter of the present invention includes all novel and non-obvious combinations and sub-combinations of the various elements, features, functions, and/or characteristics disclosed herein. Similarly, when any technical solution recites "a" or "a first" element or its equivalent, the technical solution should be understood to include the 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 by presenting new patent claims in related applications. Such new patent claims are also deemed to be included within the subject matter of the present invention, regardless of whether they relate to different inventions or to the same invention, and regardless of whether they are different from, larger than, smaller than, or the same in scope as the original patent claims.

20: Hydrogen Generation Assembly 21: Product Hydrogen Stream 22: Feedstock Delivery System 24: Fuel Handling Assembly 26: Feed Stream 28: Fuel Stream 30: Hydrogen Generation Fluid 32: Hydrogen Generation Zone 34: Output Stream 36: Steam Reforming Catalyst 38: Air Delivery Assembly 40: Purification (or Separation) Zone 42: Hydrogen-Enriched Gas Stream 44: Byproduct Stream 46: Hydrogen Selective Membrane 48: Chemical Carbon Monoxide Removal Assembly 50: Pressure Swing Adsorption (PSA) System 52: Heating Assembly 54: Exhaust Stream (or Combustion Stream) 58: Ignitor or Ignition Source 60: Burner Assembly 62: Air Flow 64: Vaporization Zone 66: Shell or Housing 68: Insulation Material 70: External Cover or Jacket 72: Hydrogen Generation Assembly 74: Feedstock Delivery System 76: Vaporization Zone 78: Hydrogen Generation Zone 80: Heating Assembly 82: Purification Zone 84: Feedstock Tank (or Container) 86: Pump 88: Hydrogen Generation Fluid 90: Feed Flow 92: Vaporizer 94: Gas-Phase Feed Flow 96: Output Flow 97: Steam Reforming Zone 98: Reforming Catalyst 99: Exhaust Flow 100: Burner Assembly 102: Blower 106: Air Flow 108: Fuel Flow 110: Combustion Zone 111: Flow Restriction Orifice 112: Permeate or Hydrogen-Enriched Gas Flow 114: Filter Assembly 116: Membrane Assembly 118: Methanation Reactor Assembly 120: Shell or Housing 122: Exhaust Port 124: Combustion Exhaust Flow 126: Control System 128: Control Assembly 130: Valve 132: Pressure Relief Valve 134: Temperature Measuring Device 136: Heat Exchange Assembly 138: Heat Exchanger 144: Hydrogen Purification Unit 146: Hydrogen Separation Zone 148: Housing 149: Main Body 150: Internal volume 152: Internal perimeter 154: First section 156: Second section 158: Retention mechanism or structure 160: Mixed gas zone 162: Permeate zone 164: Inlet port 166: Fluid flow 168: Mixed gas flow 170: Hydrogen 172: Other gases 174: Product outlet port 176: Permeate flow 178: Residual gas flow 180: Residual gas port 182: Byproduct outlet port 184: Byproduct flow 186: Hydrogen-selective membrane 188: First or mixed gas surface 190: Second or permeate surface 192: Hydrogen separation assembly 194: Membrane assembly 196: Hydrogen purification device 198: Shell or housing 200: First end plate or end frame 202: Second end plate or end frame 204: Internal compartment 205: Microporous foil screen assembly 206: Hydrogen-selective membrane 208: Microporous screen structure 210: Feed side 212: Permeate side 213: Non-porous planar sheet 214: Surface 215: Surface 216: Pores 217: Fluid passage 218: Perforated region (or portion) 219: Non-perforated region (or portion) 220: Peripheral region (or portion) 221: Boundary region (or portion) 222: Peripheral portion 223: Longitudinal axis 224: Plate or frame 225: Longitudinal axis 226: Peripheral shell 228: First support member 230: Open area 232: Frame plane 234: First opposing side 236: Second opposing side 238: Third opposing side 240: Fourth opposing side 242: First portion 244: First support plane 246: Second support member 248: Third support member 250: Second portion 252: Third portion 254: Second support plane 256: Third support plane 258: Protrusion or finger 260: Feed frame 262: Permeate frame 264: Sealing pad or sealing pad frame 266: Feed frame peripheral shell 268: Feed frame inlet conduit 270: Feed frame outlet conduit 272: Feed frame open area 274: First feed frame support member 276: Second feed frame support member 278: Third feed frame support member 302: Feed frame protrusion or finger 340: First membrane support plate 396: Hydrogen purification device 398: Shell or housing 400: First end plate or end frame 402: Second end plate or end frame 404: Internal compartment 405: Foil microporous screen assembly 406: Hydrogen-selective membrane 424: Plate or frame 430: Open area 434: First opposing side 436: Second opposing side 438: Third opposing side 440: Fourth opposing side 460: Feed frame 462: Permeate frame 464: Sealing pad or sealing pad frame

[Figure 1] is a schematic diagram of an example of a hydrogen generation assembly. [Figure 2] is a schematic diagram of an example of the hydrogen generation assembly of Figure 1. [Figure 3] is a schematic diagram of a hydrogen purification device of the hydrogen generation assembly of Figure 1. [Figure 4] is an exploded perspective view of an example of the hydrogen purification device of Figure 3. [Figure 5] is a top view of an example of a foil microporous screen assembly of the hydrogen purification device of Figure 3. [Figure 6] is a top view of an example of a microporous screen structure of the foil microporous screen assembly of Figure 5. [Figure 7] is a partial view of the microporous screen structure of Figure 6, showing another example of pores. [Figure 8] is a partial view of the microporous screen structure of Figure 6, showing an additional example of pores. [Figure 9] is a partial view of the microporous screen structure of Figure 6, showing another example of pores. [Figure 10] is a partial view of the microporous screen structure of Figure 6, showing yet another example of pores. [Figure 11] is a top view of an additional example of the foil microporous screen assembly of the hydrogen purification device of Figure 3. [Figure 12] is a top view of an example of the microporous screen structure of the foil microporous screen assembly of Figure 11. [Figure 13] is a top view of another example of the foil microporous screen assembly of the hydrogen purification device of Figure 3. [Figure 14] is a top view of another example of the foil microporous screen assembly of the hydrogen purification device of Figure 3. Figure 15 is an exploded perspective view of another example of the hydrogen purification device in Figure 3.

196: Hydrogen Purification Device

198: Shell or shell

200: First end plate or end frame

202: Second end plate or end frame

204: Internal compartment

205: Foil Microporous Screen Assembly

210: Feed side

212: Penetration side

224: Board or frame

226: Peripheral shell

228: First support component

230: Open Area

232: Frame plane

234: First opposite side

236: Second opposite side

238: Third opposite side

240: Fourth opposite side

242: Part 1

244: First support plane

246: Second support component

248: Third support component

250: Part 2

252: Part 3

254: Second support plane

256: Third support plane

258: protrusion or finger

260: Feeding frame

262: Permeate Framework

264: Sealing gasket or sealing gasket frame

266: Feed frame peripheral shell

268: Feed frame input pipeline

270: Feed frame output pipeline

272: Open area of feed frame

274: First feed frame support component

276: Second feed frame support component

278: Third feed frame support component

302: Feed frame protrusions or fingers

340: First membrane support plate

Claims (23)

A hydrogen purification device comprises: a first end frame and a second end frame, comprising: an input port configured to receive a mixed gas stream containing hydrogen and other gases; an output port configured to receive a permeate stream containing a greater concentration of hydrogen and a lower concentration of at least one of the other gases than the mixed gas stream; and a byproduct port configured to receive a byproduct stream containing at least a substantial portion of the other gases; at least one microporous foil screen assembly disposed between and secured to the first and second end frames, the at least one microporous foil screen assembly comprising: At least one hydrogen-selective membrane having a feed side and a permeate side, wherein at least a portion of the permeate stream is formed by a portion of the mixed gas stream passing from the feed side to the permeate side, wherein the remaining portion of the mixed gas stream on the feed side forms at least a portion of the by-product stream, and At least one microporous screen structure comprising a non-porous planar sheet, the non-porous planar sheet having a plurality of pores forming a plurality of fluid passages, each pore of the plurality of pores having a length defining a longitudinal axis, the plurality of pores being positioned on the non-porous planar sheet in a plurality of rows, the longitudinal axes (2) of one of the plurality of pores in one of the plurality of rows being non-parallel to the longitudinal axes of one of the plurality of pores in an adjacent row of the plurality of rows, the non-porous planar sheet including substantially opposing planar surfaces configured to provide support for the permeate side, the plurality of fluid passages extending between the opposing surfaces, wherein the at least one hydrogen selective membrane is metallurgically bonded to the at least one microporous screen structure; and A plurality of frames are disposed between the first end frame, the second end frame and the at least one foil microporous screen assembly and are secured to the first end frame and the second end frame, each of the plurality of frames including a peripheral shell defining an open area. A device as claimed in claim 1, wherein the non-porous planar sheet includes two or more discrete portions having the plurality of pores, and wherein each of the two or more discrete portions is separated from an adjacent discrete portion of the two or more discrete portions by at least one boundary portion that does not contain the plurality of pores. The device of claim 2, wherein the at least one hydrogen-selective membrane comprises two or more hydrogen-selective membranes, and wherein a different one of the two or more hydrogen-selective membranes is metallurgically bonded to each of the two or more discrete portions. A device as claimed in claim 3, wherein each of the two or more hydrogen selective membranes is sized to be larger than the corresponding discrete portion so that a peripheral portion of the hydrogen selective membrane contacts one or more portions of the non-porous planar sheet that do not include the plurality of pores. The device of claim 1, wherein the at least one hydrogen selective membrane is diffusion bonded to the at least one microporous screen structure. A hydrogen purification device comprises: a first end frame and a second end frame, comprising: an input port configured to receive a mixed gas stream containing hydrogen and other gases; an output port configured to receive a permeate stream containing a greater concentration of hydrogen and a lower concentration of at least one of the other gases than the mixed gas stream; and a byproduct port configured to receive a byproduct stream containing at least a substantial portion of the other gases; at least one microporous foil screen assembly disposed between and secured to the first and second end frames, the at least one microporous foil screen assembly comprising: At least one hydrogen-selective membrane having a feed side and a permeate side, wherein at least a portion of the permeate stream is formed by a portion of the mixed gas stream passing from the feed side to the permeate side, wherein the remaining portion of the mixed gas stream on the feed side forms at least a portion of the by-product stream, and At least one microporous screen structure comprising a non-porous planar sheet having a plurality of stadium-shaped pores forming a plurality of fluid passages, at least one of the plurality of stadium-shaped pores having a length greater than ten times the radius of the pore, the planar sheet including substantially opposing planar surfaces configured to provide support for the permeate side, the plurality of fluid passages extending between the opposing surfaces, wherein the at least one hydrogen-selective membrane is metallurgically bonded to the at least one microporous screen structure; and a plurality of frames disposed between the first and second end frames and the at least one foil microporous screen assembly and secured to the first and second end frames, each of the plurality of frames including a peripheral shell defining an open area. The device of claim 6, wherein the non-porous planar sheet comprises a length and a width, and the plurality of stadium-shaped apertures are disposed along a substantial portion of the length and a substantial portion of the width of the non-porous planar sheet. A device as claimed in claim 7, wherein one or more of the plurality of stadium-shaped apertures has a length that is a substantial fraction of the width of the non-porous planar sheet. The device of claim 6, wherein the plurality of stadium-field-shaped apertures are positioned in a plurality of rows on the non-porous planar sheet such that (1) the longitudinal axes of the plurality of stadium-field-shaped apertures in each of the plurality of rows are parallel to each other and to the plurality of stadium-field-shaped apertures in an adjacent row of the plurality of rows, and (2) the length of each stadium-field-shaped aperture in each of the plurality of rows is different from the length of one or more stadium-field-shaped apertures in an adjacent row of the plurality of rows. A device as claimed in claim 6, wherein the non-porous planar sheet includes two or more discrete portions having the plurality of stadium-field-shaped pores, and wherein each of the two or more discrete portions is separated from an adjacent discrete portion of the two or more discrete portions by at least one boundary portion that does not contain the plurality of stadium-field-shaped pores. The device of claim 10, wherein the at least one hydrogen selective membrane comprises two or more hydrogen selective membranes, and wherein a different one of the two or more hydrogen selective membranes is metallurgically bonded to each of the two or more discrete portions. A device as claimed in claim 11, wherein each of the two or more hydrogen selective membranes is sized to be larger than the corresponding discrete portion so that a peripheral portion of the hydrogen selective membrane contacts one or more portions of the non-porous planar sheet that do not include the plurality of stadium-shaped pores. The device of claim 6, wherein the at least one hydrogen selective membrane is diffusion bonded to the at least one microporous screen structure. A foil microporous screen assembly comprising: At least one hydrogen-selective membrane having a feed side and a permeate side, wherein the at least one hydrogen-selective membrane is configured to receive a mixed gas stream, form a permeate stream from a portion of the mixed gas stream that passes from the feed side to the permeate side, and form a by-product stream from a remaining portion of the mixed gas stream that remains on the feed side; and At least one microporous screen structure comprising a non-porous planar sheet having a plurality of pores forming a plurality of fluid passages, each pore of the plurality of pores having a length defining a longitudinal axis, the plurality of pores being positioned on the non-porous planar sheet in a plurality of rows, the longitudinal axis of one of the plurality of pores in one of the plurality of rows being (2 ) is non-parallel to a longitudinal axis of a pore in an adjacent row in the plurality of rows, the non-porous planar sheet includes substantially opposing planar surfaces configured to provide support for the permeate side, the plurality of fluid passages extending between the opposing surfaces, wherein the permeate side of the at least one hydrogen-selective membrane is metallurgically bonded to the at least one microporous screen structure. The assembly of claim 14, wherein the non-porous planar sheet comprises two or more discrete portions having the plurality of pores, and wherein each of the two or more discrete portions is separated from an adjacent discrete portion of the two or more discrete portions by at least one boundary portion that does not contain the plurality of pores. The assembly of claim 15, wherein the at least one hydrogen-selective membrane comprises two or more hydrogen-selective membranes, and wherein a different one of the two or more hydrogen-selective membranes is metallurgically bonded to each of the two or more discrete portions. The assembly of claim 16, wherein each of the two or more hydrogen selective membranes is sized to be larger than the corresponding discrete portion such that a peripheral portion of the hydrogen selective membrane contacts one or more portions of the non-porous planar sheet that do not include the plurality of stadium-shaped pores. The assembly of claim 14, wherein the at least one hydrogen selective membrane is diffusion bonded to the at least one microporous screen structure. A foil microporous screen assembly comprising: At least one hydrogen-selective membrane having a feed side and a permeate side, wherein the at least one hydrogen-selective membrane is configured to receive a mixed gas stream, form a permeate stream from a portion of the mixed gas stream that passes from the feed side to the permeate side, and form a by-product stream from a remaining portion of the mixed gas stream that remains on the feed side; and At least one microporous screen structure comprising a non-porous planar sheet having a plurality of stadium-shaped pores forming a plurality of fluid passages, at least one of the plurality of stadium-shaped pores having a length greater than ten times the radius of the pore, the planar sheet including substantially opposing planar surfaces configured to provide support for the permeate side, the plurality of fluid passages extending between the opposing surfaces, wherein the permeate side of the at least one hydrogen-selective membrane is metallurgically bonded to the at least one microporous screen structure. The assembly of claim 19, wherein the non-porous planar sheet comprises two or more discrete portions having the plurality of stadium-shaped pores, and wherein each of the two or more discrete portions is separated from an adjacent discrete portion of the two or more discrete portions by at least one boundary portion that does not contain the plurality of pores. The assembly of claim 20, wherein the at least one hydrogen-selective membrane comprises two or more hydrogen-selective membranes, and wherein a different one of the two or more hydrogen-selective membranes is metallurgically bonded to each of the two or more discrete portions. The assembly of claim 21, wherein each of the two or more hydrogen selective membranes is sized to be larger than the corresponding discrete portion such that a peripheral portion of the hydrogen selective membrane contacts one or more portions of the non-porous planar sheet that do not include the plurality of pores. The assembly of claim 19, wherein the at least one hydrogen selective membrane is diffusion bonded to the at least one microporous screen structure.