Patent Description:
The presently disclosed systems may be used to obtain hydrogen from a hydrogen liquid carrier. In particular, the presently disclosed systems may be configured for obtaining hydrogen from a hydrogen liquid carrier upon flowing the hydrogen liquid carrier through catalyst equipped flow conduit.

With the limited supply of fossil fuels and their adverse effect on the climate and the environment, it has become a global priority to seek alternate sources of energy that are clean, abundant, and sustainable. While sources such as solar, wind, and hydrogen can meet the world's energy demand, considerable challenges remain to find materials that can store and/or convert energy efficiently.

Efficient hydrogen generation from a hydrogen liquid carrier is a key enabling technology for the advancement of hydrogen and fuel cell technologies in applications including stationary power, portable power, and transportation. Hydrogen has the highest energy per mass of any fuel. Its low ambient temperature density, however, results in a low energy per unit volume, therefore requiring the development of advanced storage methods that have the potential for higher energy density. Hydrogen is considered to be an ideal fuel for the transportation industry. However, considerable challenges related to hydrogen generation from a hydrogen liquid carrier still need to be addressed in order to use hydrogen for transportation purposes.

At ambient conditions, hydrogen is a volatile gas. One kg of hydrogen occupies <NUM><NUM> (~<NUM>/m<NUM> ) - a volume that may be impractically large for certain hydrogen-based energy applications. One goal in hydrogen utilization, therefore, is the reduction of hydrogen volume, either by compression, liquefaction, adsorption to high surface area materials, or embedding in solid compounds. Solid state hydrogen storage may result in the highest hydrogen volumetric densities, exceeding a volumetric density of liquid hydrogen, for example, by more than a factor of two. Other challenges from the materials perspective may include combined volumetric and gravimetric hydrogen density that may be required for use in the transportation industry (e.g., <NUM> mass % H<NUM> and <NUM> kgH<NUM> /m<NUM>, respectively), suitable thermodynamic stability for the working temperature (e.g., - <NUM> to <NUM>), and sufficiently fast reaction kinetics to allow rapid hydrogen uptake and delivery (e.g., refueling of <NUM> of H<NUM> in few minutes).

Metal hydrides, such as metal borohydrides, may offer a hydrogen storage medium. Metal borohydrides may be dissolved in a liquid, such as water, resulting in a hydrogen liquid carrier. Metal borohydrides may be capable of storing hydrogen at targets levels of <NUM> wt % H<NUM> and <NUM> of H<NUM> per liter of the liquid carrier. Under appropriate temperature and pressure conditions, metal borohydrides may release hydrogen that can be used as a fuel (e.g., for a fuel cell).

Efficiently releasing hydrogen from such a liquid carrier and/or gaining access to most or all of the hydrogen stored in a liquid carrier, however, may present certain challenges. Thus, there is a need to develop solutions for the efficient production of hydrogen from a hydrogen liquid carrier resulting in a spent carrier containing a low concentration of hydrogen.

<CIT> discloses a fuel cell system including a fuel cell stack for generating electric energy by an electrochemical reaction of hydrogen and oxygen; a hydride tank for storing a liquid hydride; a liquid catalyst tank for storing a liquid catalyst for promoting a hydrogen gas generation reaction from the liquid hydride; a reaction flow channel for promoting laminar flow of the liquid hydride and the liquid catalyst; and a hydrogen separator for storing the hydrogen gas generated from the reaction flow channel and transferring the hydrogen gas to the fuel cell stack.

Consistent with a disclosed embodiment, a reaction chamber for generating hydrogen gas is provided. The reaction chamber for generating hydrogen gas using a hydrogen liquid carrier line includes a channel including a catalyst for causing the hydrogen gas to be produced from the hydrogen liquid carrier, the channel including an inlet end for the hydrogen liquid carrier, an outlet end for a spent carrier, and at least one mixing element to enchance mixing of the hydrogen liquid carrier. The reaction chamber also includes a valve for controlling a rate of flow of the hydrogen liquid carrier flowing through the channel, a gas outlet for evacuating the hydrogen gas generated in the channel, and at least one processor configured to receive at least one signal from a power consuming system indicating a demand for the hydrogen gas, and to control the valve to adjust the rate of flow of the hydrogen liquid carrier to meet the demand for the hydrogen gas.

The foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the claims.

The accompanying drawings are not necessarily to scale or exhaustive. Instead, the emphasis is generally placed upon illustrating the principles of the inventions described herein. These drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments consistent with the disclosure and, together with the detailed description, serve to explain the principles of the disclosure. In the drawings:.

Reference will now be made in detail to exemplary embodiments, discussed with regards to the accompanying drawings. In some instances, the same reference numbers will be used throughout the drawings and the following description to refer to the same or like parts. Unless otherwise defined, technical and/or scientific terms have the meaning commonly understood by one of ordinary skill in the art. The disclosed embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosed embodiments. It is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the disclosed embodiments. Thus, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

In various embodiments of the present invention, a system for storing a hydrogen liquid carrier and related chemical compounds and/or byproducts is disclosed in connection with a hydrogen generating system <NUM> for generating hydrogen for powering a fuel cell. In an illustrative embodiment shown in <FIG>, hydrogen generating system <NUM> may include a storage system <NUM> for storing a hydrogen liquid carrier. Storage system <NUM> may include a carrier tank <NUM> having several chambers (e.g., chambers <NUM> and <NUM>), a carrier outlet line <NUM>, (arrow <NUM> indicates a flow of a hydrogen liquid carrier), a spent carrier inlet line <NUM> (arrow <NUM> indicates a flow of a spent carrier), a reaction chamber <NUM> for producing hydrogen, and a catalyst <NUM> for facilitating generation of hydrogen from a hydrogen liquid carrier. In an illustrative embodiment shown in <FIG>, a hydrogen outflow line 125A (arrow <NUM> indicates the direction of hydrogen flow) delivers hydrogen from reaction chamber <NUM> to a hydrogen storage chamber <NUM>. Chamber <NUM> may then deliver hydrogen via a hydrogen line 125B to a fuel cell <NUM>.

In various embodiments, a hydrogen liquid carrier may include metal hydrides, and in some embodiments, metal borohydrides. In an illustrative embodiment, metal borohydrides may include any chemical compound that may be described by formula M<NUM>-BH<NUM>, where M<NUM> may be a metal selected from a column I of the periodic table of elements, or alloys of metals selected from a column I of the periodic table of elements. In an illustrative embodiment, metal M<NUM> may include any of Li, Na, K, Rb, Cs, Ca, and Fr. In some embodiments, however, metal M<NUM> may be selected from column II of the periodic table and may include Mg and Be. Alternatively, M<NUM> metal may also include Al, Ti, Be, Ca or other suitable metals.

In some embodiments, a hydrogen liquid carrier may include chemical compounds containing more than one metal. In an illustrative embodiment, the hydrogen liquid carrier may include ternary hydrides with a chemical compound described by a formula M1aM1b -H<NUM>, where M1a and M1b may be metals. In an example embodiment, M1a may include Li, Na, K, Rb, Cs, Ti, Be, Fr, or other suitable metals. In an example embodiment, M1b may include Al, Ni, Be, Ca, Ti, or other suitable metals. Additionally or alternatively, the hydrogen liquid carrier may include quaternary hydrides, such as Li-B-H or other suitable quaternary hydrides described by formula M1a-H<NUM>.

The hydrogen liquid carrier may include other chemical compounds other than an aqueous solution of metal hydrides or metal borohydrides. For example, the hydrogen liquid carrier may include solubility-enhancing chemicals or stabilizers, such as soluble metal hydroxides (e.g., sodium hydroxide). Other usable stabilizers may include potassium hydroxide or lithium hydroxide, among others. The liquid component of the hydrogen liquid carrier may include any suitable liquid. Such liquids may include water or alcohols. The liquid carrier may also include additives, stabilizers, or other reaction enhancers, such as sodium hydroxide as a stabilizer, a polyglycol as a surfactant, or many others.

In various embodiments, a hydrogen liquid carrier may also be referred to as a liquid carrier, carrier or a hydrogen-based liquid fuel. As used herein, unless otherwise specified, the term "liquid carrier" or "hydrogen liquid carrier" may refer to a carrier configured to release hydrogen under appropriate temperature and pressure conditions in the proximity of a catalyst. As used herein, unless otherwise specified the term "depleted" when referring to a spent carrier describes the hydrogen liquid carrier after either fully or partially releasing hydrogen. For example, when the carrier is fifty percent depleted, half of all the available hydrogen has been released by the carrier as compared to the maximum amount of hydrogen that can be released by the carrier. In various embodiments, a depleted carrier may also be referred to as a spent carrier. In some embodiments, the spent carrier may include a partially depleted carrier and may contain some hydrogen that can still be released from the carrier.

In various embodiments, a spent carrier is formed during a reaction when hydrogen is released from a hydrogen liquid carrier. In an example embodiment, a reaction may include the reaction of metal borohydrides (described by formula M<NUM>-BH<NUM>) with water leading to M<NUM>-metaborate formation, where M<NUM> Li, Na, K, Rb, Cs, Ti, Be, Fr, or other suitable metals.

In various embodiments, the chemical reaction between reactants, such as M<NUM>-BH<NUM> and water may be performed when reactants are dissolved in water. In an illustrative embodiment, an aqueous solution of M<NUM>-BH<NUM> may be used as a hydrogen liquid carrier, and via chemical reaction, may release hydrogen and form a spent carrier, that may be an aqueous solution of metal borate. While an aqueous solution of metal borate is one example of the spent carrier, the spent carrier may include various other chemical compounds. In an illustrative process, when metal hydrides are used as a hydrogen liquid carrier, the resulting spent carrier may include metals and metaborates.

In various embodiments, a hydrogen liquid carrier releases hydrogen in a reaction chamber <NUM> when in contact with catalyst <NUM>. In various embodiments, catalyst <NUM> may include any suitable catalyst for facilitating hydrogen production and may include transition metals, such as Fe, Co, Cu, Ni, Ru, Pt, B, alloys, and combinations thereof. In some embodiments, catalyst <NUM> may include a Group III metal, Cobalt-P, Cobalt-B, Cobalt-Ni, P and Cobalt-NIB or Electriq Global™ E-Switch. In various embodiments, generated hydrogen is delivered via outflow line 125A to hydrogen storage chamber <NUM> and, subsequently, to fuel cell <NUM>. In various embodiments, system <NUM> may include pressure sensors and pressure pumps (not shown in <FIG>) facilitating the flow of a hydrogen liquid carrier, a spent carrier, and flow of hydrogen through lines <NUM>, <NUM>, 125A and 125B. For example, a pump may be used to pump the hydrogen liquid carrier into a pressurized reaction chamber <NUM>. In some embodiments, the hydrogen liquid carrier may flow into reaction chamber <NUM> as hydrogen is released from reaction chamber <NUM> and stored in hydrogen chamber <NUM>. In an example embodiment, a pump may be used to transfer hydrogen from chamber <NUM> to chamber <NUM>.

In various embodiments, system <NUM> includes controllers that is operated by a computing system <NUM> schematically shown in <FIG>. Computing system <NUM> includes a computer-readable storage medium <NUM> that can retain and store data and program instructions for execution by a processor <NUM>. Storage medium <NUM> may include, for example, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, or any suitable combination of such devices or other suitable electronic storage devices. A non-exhaustive list of more specific examples of the computer readable storage medium may include a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM) a memory stick, or/and the like.

Program instructions stored on computer-readable storage medium <NUM> may include assembler instructions, machine dependent instructions, firmware instructions, source code or object code written in any combination of one or more programming languages, including an object oriented programming languages, procedural programming languages or functional programming languages. The programming language may be Fortran, Lisp, C++ or the like. The program instructions may be executed by processor <NUM> of computing system <NUM>. In some embodiments, the computing system may provide a user interface <NUM> for modifying data, for updating program instructions or for entering various parameters used by the program instructions.

In various embodiments, processor <NUM> of computer system <NUM> is configured to receive a signal (also referred to as indicator) indicating a demand for the hydrogen gas. In response processor <NUM> controls one or more valves to adjust the rate of flow of the hydrogen liquid carrier to meet the demand for the hydrogen gas. In an illustrative embodiment, the signal indicating the demand for the hydrogen gas is generated by any power consuming system configured to use hydrogen as a source of fuel. For example, for system <NUM> installed on a vehicle, the signal indicating the demand for hydrogen gas may originate from or may be associated various vehicle systems (e.g., power control processors, accelerator systems, hydrogen combustion control systems, advanced driver assist systems (ADAS), autonomous vehicle control systems, etc.).

<FIG> shows an illustrative embodiment of system <NUM> including carrier tank <NUM>, reactor chamber <NUM>, hydrogen supply outlet 125A, catalyst <NUM>, as well as a reactor stop valve <NUM>, a main carrier rail <NUM>, a drain valve <NUM>, and a carrier supply valve <NUM>. In various embodiments, carrier supply valve <NUM> may supply a hydrogen liquid carrier from the external source to carrier tank <NUM>, a drain valve <NUM> may drain a spent carrier from reactor <NUM>, and reactor stop valve <NUM> may control the flow of a hydrogen liquid carrier from the carrier tank to reactor <NUM>. In an illustrative embodiment, system <NUM> depicted in <FIG> may produce hydrogen from a hydrogen liquid carrier in discontinuous, periodic cycles. In such an embodiment, main carrier rail <NUM> is used for supplying a hydrogen liquid carrier from carrier tank <NUM> to reactor chamber <NUM> as well as for discharging a spent carrier from reactor chamber <NUM> via drain valve <NUM>. In an example embodiment, system <NUM> operates by first flowing the hydrogen liquid carrier via rail <NUM> from carrier reservoir <NUM> to reactor chamber <NUM>. There, the hydrogen liquid carrier reacts with catalyst <NUM> to release hydrogen, which is carried from reactor chamber <NUM> by hydrogen supply outlet 125A. After completion of a hydrogen production cycle, or at any other suitable time, a spent hydrogen liquid carrier may be collected from reactor chamber <NUM>, flowed through carrier rail <NUM>, and may exit from system <NUM> via drain valve <NUM>.

In contrast to the cyclical hydrogen generating system <NUM> of <FIG>, the embodiment shown in <FIG> may operate to generate hydrogen in a more continuous manner. For example, a hydrogen liquid carrier may be flowed from an upper cylinder head as shown for example by arrows <NUM> and collected at the bottom of chamber <NUM> as a spent carrier. In various embodiments, catalyst <NUM> may be deposited on walls <NUM> of chamber <NUM> and may facilitate hydrogen release from the hydrogen liquid carrier as the carrier passes in proximity of walls <NUM>. In various embodiments, hydrogen may be collected at the top of chamber <NUM> for example at hydrogen manifold <NUM> for flowing to hydrogen storage chamber <NUM>, or for flowing to a fuel cell <NUM> (or to any other hydrogen storage or consumption unit).

In various embodiments, chamber <NUM> may include a liquid cooling system, such as for example a cooling water jacket <NUM> as shown in <FIG>. Jacket <NUM> may be configured to cool walls <NUM> of reaction chamber <NUM>. The cooling jackets may include a liquid disposed within the jackets. In some embodiments, the cooling jackets may contain a cooling fluid to promote thermal management. The cooling fluid may consist of water, glycol, or some other gas or liquid coolant or combination thereof. The cooling jacket may contain a number of fins or baffles inside the jacket to promote heat transfer. Alternatively, the cooling jackets may include a shell and tube heat exchanger or other known heat transfer device. The cooling jackets may be included within the walls of reaction chamber <NUM> by various alternative structures.

Another embodiment of reaction chamber <NUM> is shown in <FIG>. This embodiment includes a channel <NUM> with an inlet <NUM> for receiving a hydrogen liquid carrier and an outlet <NUM> for outputting a spent carrier. The flow rate of the hydrogen liquid carrier is controlled via an inlet valve <NUM> and an outlet valve <NUM> by a flow rate controller <NUM>. Reaction chamber <NUM> includes a catalysts 403A and 403B. In an example embodiment, catalyst 403A may be deposited over at least a portion of a surface of walls <NUM> of channel <NUM>. Additionally or alternatively, catalyst 403B may be provided within the channel.

In various embodiments, catalyst 403B may be configured to be removable and may be secured to channel <NUM> by screws, bolts, clamps, clips, locking mechanisms, welding, adhesive or any other means. In an illustrated embodiment, catalyst 403B may include multiple porous sheets positioned within the flow formed by the hydrogen liquid carrier flowing through channel <NUM>. In an illustrative embodiment, catalyst 403B may include porous sheets positioned across the flow, aligned with the flow or arranged at an angle to the flow. In some embodiments, catalyst 403B may include multiple porous sheets with some sheets positioned at a first angle to the flow and some sheets positioned at a second angle to the flow. For example, some sheets may be positioned across the flow, and some sheets may be positioned along the flow.

While the present disclosure provides an example configuration of catalyst 403B, it should be noted that the disclosure is not limited to a particular configuration of catalyst 403B. For example, catalyst 403B may be configured in a substantially planar configuration, cylindrical configuration, as a porous block, as a porous cylinder, or as a two-dimensional or three-dimensional mesh, or in any other suitable configuration. In some embodiments, catalyst 403B may be configured to have various other shapes, for example, to promote a flow of the hydrogen liquid carrier within channel <NUM>, or to maximize a surface wetted area of catalyst 403A or catalyst 403B by the hydrogen liquid carrier. In some embodiments, catalyst 403B may be configured as a corrugated sheet or mesh. In other embodiments, catalyst 403B may be arranged in a structured packing configuration. This may include known structured packing configurations, such as a honeycomb, gauze, knitted, sheet metal, grid or other known structured packing configuration. In other embodiments, catalyst 403B may include a spherical or tubular configuration. In some embodiments, channel <NUM> of reaction chamber <NUM> may have multiple regions containing catalyst 403A or catalyst 403B.

In various embodiments, the catalyst material forming catalyst 403A or catalyst 403B may include a metal structure and a catalytic coating on the metal structure. In some embodiments, the coating may include Ni. The coating may be formed as a single layer or may include multiple layers (e.g., layers formed through different processes and/or layers including different materials, etc.). While the present disclosure provides examples of a catalyst with a Ni coating, it should be noted that aspects of the disclosure in their broadest sense, are not limited to any particular composition or structure of catalyst 403A or catalyst 403B.

In some embodiments, the metal structure may be composed of stainless steel. The Ni coating on the metal structure may require a specific roughness value or range of roughness values. In some embodiments, the Ni layer may have a roughness value between the range of <NUM> - <NUM> calculated as the Roughness Average (Ra). While the present disclosure provides examples of exemplary roughness values, it should be noted that aspects of the disclosure in their broadest sense, are not limited to these particular values.

In various embodiments, the flow rate of the hydrogen liquid carrier is determined in view of a hydrogen release rate and a requested or required rate of hydrogen production. For example, in some cases, to achieve a higher rate of hydrogen release from the hydrogen liquid carrier, the flow rate of the hydrogen liquid carrier to a reaction chamber may be increased. In various embodiments, the flow rate of the hydrogen liquid carrier may be calibrated or correlated with the rate of hydrogen release or hydrogen depletion rate. The calibrated or correlation data may be stored in a memory unit (e.g., a computer-readable storage medium <NUM>) as an operational data that can be accessed by a flow controller. In various embodiments, the flow controller may be controlled by computing system <NUM>.

In various embodiments, the flow rate of the hydrogen liquid carrier may affect the extent to which the hydrogen liquid carrier is depleted (e.g., what percentage of the available hydrogen in the hydrogen liquid carrier is released). In some embodiments, any of the length of channel <NUM>, the amount of catalyst 403A and 403B, or the placement of catalyst 403B within channel <NUM> may affect the amount of depletion of the hydrogen liquid carrier. In some embodiments, channel <NUM> may be configured to result in the fully depleted or nearly fully depleted hydrogen liquid carrier (e.g., depletion percentages nearing or equaling one hundred percent) in view of a certain flow rate of the hydrogen liquid carrier. In some cases, the design of channel <NUM> may facilitate complete depletion of the hydrogen liquid carrier even when reaction chamber <NUM> is operating at a maximum output level within allowed operational parameters.

One or more hydrogen outlets may be located in any suitable location within reaction chamber <NUM>. In some cases, hydrogen outlets 405A-405C may be located along an upper wall portion of channel <NUM>. In an illustrative embodiment, the flow rate of hydrogen from channel <NUM> may be controlled by a hydrogen flow controller <NUM> operating valves 421A-421C for hydrogen outlets 405A-405C. In various embodiments, hydrogen flow controller <NUM> may be operated by computing system <NUM> of system <NUM>.

In an illustrative embodiment, processor <NUM> of system <NUM> receives a signal indicating a demand for the hydrogen gas and adjust a rate of flow of the liquid carrier in the channel using flow rate controller <NUM> controlling valves <NUM> and <NUM>, based on the received demand. In various embodiments, processor <NUM> is configured to receive at least one indicator of the demand for hydrogen gas, and adjust the rate of flow of the hydrogen liquid carrier to meet the demand for hydrogen gas. Additionally, or alternatively, processor <NUM> may operate hydrogen flow controller <NUM> to discharge an amount of the hydrogen gas generated in the channel based on the received demand.

The indicator of the demand for hydrogen gas includes signals generated by any system configured to use hydrogen. The signals may be generated by one or more sensors, such as pressure sensors, hydrogen flow rate sensors, or the like. In some embodiments, the amount of the hydrogen gas discharged by hydrogen flow controller <NUM> may be detected by a sensor, such as a hydrogen pressure sensor, hydrogen flow rate sensor and/or the like. In various embodiments, the pressure sensor may be installed in a region of chamber <NUM> that contains hydrogen. In various embodiments, the demand for hydrogen gas may correspond to a need for more hydrogen gas, a need for less hydrogen gas, or a need for a maintained level of hydrogen gas supply. Flow rate controller <NUM> and hydrogen flow controller <NUM> respond by controlling the valves (e.g. valves <NUM> and <NUM> controlled by flow rate controller <NUM>, and valves 421A-421C controlled by hydrogen flow controller <NUM>) to increase, decrease or maintain a supply of hydrogen gas.

In some embodiments, reaction chamber <NUM> main include channel <NUM> with several subsections, with each subsection having a subsection outlet for evacuating the hydrogen gas. In some embodiments, a number of subsections may be selected such that the carrier is depleted after passing through all the subsections, resulting in a spent carrier, and wherein the spent carrier is discharged from the reaction chamber <NUM> via outlet <NUM>. In some embodiments, reaction chamber <NUM> may include sensors for monitoring hydrogen pressure at various subsection outlets of channel <NUM>.

<FIG> show various embodiments for controlling a flow of a hydrogen liquid carrier within chamber <NUM> consistent with various aspects of the disclosed embodiments. In an illustrative embodiment shown in <FIG>, the flow of the hydrogen liquid carrier may enter chamber <NUM> via inflow inlet <NUM>. In various embodiments, flow control fins <NUM> may be present within chamber <NUM>. Flow control fins <NUM> may be configured to move in various directions as schematically illustrated by arrows <NUM> or may be configured to rotate around central regions <NUM> as schematically illustrated by arrows <NUM>. Fins <NUM> may be moved or rotated in any suitable way. In various embodiments, the position and orientation of fins <NUM> may be controlled by computing system <NUM>. In an illustrative embodiment, fins <NUM> may be positioned to create vortices within the flow of the hydrogen liquid carrier to enhance carrier mixing and to maximize carrier interaction with catalyst 403A and 403B. In various embodiments, chamber <NUM> may include one or more fins <NUM>. In some embodiments, catalyst 403B may be deposited over fins <NUM>.

In an illustrative embodiment shown in <FIG>, chamber <NUM> may include more than one inlet for entering the hydrogen liquid carrier. For example, as shown in <FIG>, chamber <NUM> may include an inlet 601A and an inlet 601B that, in some cases, may be positioned at an angle θ relative to inlet 601A, as shown in <FIG>. In some embodiments, flow controllers may control the flow rate of the hydrogen liquid carrier into inlet 601A and inlet 601B to provide an adequate flow (e.g., the flow rate and the flow mixing) of the hydrogen liquid carrier through chamber <NUM>. Various other configurations of the hydrogen liquid carrier inlets are also possible. For example, chamber <NUM> may have more than two inlets. Chamber <NUM> may have a set of inlets that are distributed throughout a portion or entirety of chamber <NUM>, etc..

In some configurations, inlets such as 601A and 601B may be parallel, perpendicular or on opposite sides of the reaction chamber relative to one another. Another example of a carrier inlet is shown in <FIG>. Particularly, inlet <NUM> may be positioned to deliver hydrogen liquid carrier tangentially relative to walls of chamber <NUM>, as shown in <FIG> by streamline <NUM>. In an illustrative embodiment, the hydrogen liquid carrier may have a rotational velocity along the walls of chamber <NUM>. Chamber <NUM> includes a mixing element <NUM> placed within chamber <NUM> configured to enhance mixing of the hydrogen liquid carrier. In an illustrative embodiment, mixing element <NUM> may be stationary. In some embodiments, mixing component <NUM> may rotate around axis <NUM>. In some embodiments axis <NUM> may be aligned with an axis of chamber <NUM>, and in some embodiments, axis <NUM> may not be aligned with the axis of chamber <NUM>.

<FIG> shows an illustrative embodiment including multiple inlets, such as inlets 801A-801C that may be present in chamber <NUM>. Each of the inlets 801A-801C may be associated with a corresponding flow controller 802A-802C. In various embodiments, each flow controller 802A-802C may separately control the flow of the hydrogen liquid carrier to a corresponding inlet. In various embodiments, chamber <NUM> may include a hydrogen outlet <NUM> with respective a hydrogen flow controller <NUM>. Controller <NUM> may allow hydrogen to be released from chamber <NUM>. In some embodiments, controller <NUM> enables hydrogen release depending on pressure and temperature within chamber <NUM>, as sensed by sensor <NUM>.

In various embodiments, chamber <NUM> may include an inlet <NUM> and a corresponding flow controller <NUM> for flowing a liquid <NUM> that may be used to facilitate hydrogen generation within chamber <NUM>. In some embodiments, liquid <NUM> may include chemical compounds that may be used for forming solutions of the hydrogen liquid carrier. Such chemical compounds may include solubility-enhancing chemicals or stabilizers, such as soluble metal hydroxides, such as LiOH, NaOH, CaOH or KOH or the like. In various embodiments, liquid <NUM> may include any liquid capable of reacting with a hydrogencontaining chemical compound (e.g., metal borohydride), and may include, but is not limited to, water. The liquid solvent may also include additives, stabilizers, or other reaction enhancers, such as a surfactant, or others. In various embodiments, the mixture of a liquid and hydrogen containing chemical compound may result in a colloid or a suspension. In some embodiments, liquid <NUM> may include destabilizing agents.

In various embodiments, chamber <NUM> depicted in <FIG> may have an outlet <NUM> and related flow controller <NUM> for discharging a depleted (spent) carrier from chamber <NUM>. In various embodiments, flow controllers 802A-802C, <NUM>, <NUM>, <NUM>, and <NUM> may be used to control pressure within chamber <NUM>. In various embodiments, computer system <NUM> may be used to control various flow controllers shown in <FIG>.

<FIG>, shows an illustrative embodiment of chamber <NUM> with an inlet <NUM>, a hydrogen outlet <NUM>, and a spent carrier outlet <NUM>, with chamber <NUM> including various elements <NUM> designed to affect the flow within the chamber. In various embodiments, flow elements <NUM> may include two- and three-dimensional mesh elements, or porous cylinders. In some embodiments, elements <NUM> may be coated by a catalyst. In various embodiments, the catalyst may include a metal structure (e.g., a support structure) and a catalytic coating on the metal structure. In some embodiments, the coating may include an inner layer including Ni and one or more outer layers including a catalyst material.

<FIG> shows an illustrative embodiment of chamber <NUM>, where inlet <NUM> and outlet <NUM> are located on the bottom side <NUM> of the chamber. The flow of the hydrogen liquid carrier may turn at the top side of chamber <NUM> resulting in added vortices in the proximity of hydrogen outlet <NUM>. In various embodiments, chamber <NUM> may be positioned vertically, such that hydrogen outlet <NUM> is in the top portion of chamber <NUM>. The illustrative embodiment of chamber <NUM> depicted in <FIG> may be useful from a design standpoint, as the fluid and gas connections are on different sides of the chamber, which may facilitate mixing within the flow due to flow turning at the top side of chamber <NUM>.

<FIG> shows an illustrative design of chamber <NUM> configured to have multiple channels. In an illustrative embodiment, each channel may have walls covered with a catalyst. In various embodiments, channels may have different cross-sections. As an illustrative example, middle channels, such as channels 1101A and 1101B may have a first cross-section, channels 1102A and 1102B may have a second cross-section different from a first cross-section, and channel <NUM> may have a third cross-section different from the first or the second cross-section. In some embodiments, the cross-sections of the channels may be chosen such that the flow at least in the proximity of the outlets of the channels promotes mixing. It should be noted that aspects of the channels discussed above are only illustrative and various other embodiments are possible. For example, channels may all have the same cross-section.

In various embodiments, the presence of multiple channels may allow for additional (finer) control of the flow of the hydrogen liquid carrier. For example, in some embodiments, each channel may have separate flow control. In some embodiments, some channels may be open for flow and some channels may be closed for flow depending on requirements for the rate of hydrogen release. In some embodiments, channels may differ in catalysts present in the channels or may differ in channel wall roughness. In some embodiments, channels may differ in the chemical constituents of the hydrogen liquid carrier intended to flow through the channel. For example, channels 1101A and 1101B may flow aqueous solutions of a hydrogen liquid carrier with a first ratio of solvent-to-solute, while channels 1102A and 1102B may flow aqueous solutions of a hydrogen liquid carrier with a second ratio of solvent-to-solute. In some illustrative embodiments, the hydrogen liquid carriers flowed through channels 1102A and 1102B may be more concentrated than the hydrogen liquid carrier flowed through channels 1101A and 1101B.

In some embodiments, reaction chamber <NUM> may include a variable cross-section. In an illustrative embodiment of a cross-section of chamber <NUM>, shown in <FIG>, chamber <NUM> may include a gradually expanding profile, which may result in a slowing of the flow of the hydrogen liquid carrier (the flow of the hydrogen liquid carrier is indicated by flow lines <NUM>). In an illustrative embodiment, the expansion of the volume of chamber <NUM> may facilitate control of hydrogen release rates from the hydrogen liquid carrier that is partially depleted at the proximity of the exit of chamber <NUM>. In the example embodiment shown in <FIG>, chamber <NUM> may include catalytic walls <NUM> presented in chamber <NUM> as shown in <FIG>. In various embodiments, hydrogen outlet channels <NUM> may be present in chamber <NUM>, with the number of hydrogen channels per unit area increasing at the proximity of the exit of chamber <NUM>.

In various embodiments, the carrier depletion may increase towards the end of chamber <NUM> as shown for example by a curve <NUM>, which represents hydrogen concentration in a hydrogen liquid carrier over the length of chamber <NUM>. In various embodiments, flow velocity may decrease as shown for example by a curve <NUM>, which represents a flow velocity of the hydrogen liquid carrier as it traverses the length of chamber <NUM>. In various embodiments, a decrease in the flow rate of the hydrogen liquid carrier and an increase in the wetted catalytic surface due to the presence of catalytic walls <NUM> may offset the depletion of the hydrogen liquid carrier resulting in constant or near constant hydrogen release rate over the length profile of chamber <NUM>, as indicated by curve <NUM>. It should be noted that the hydrogen release rate is not necessarily required to be constant throughout chamber <NUM> and any other suitable hydrogen release rate may be adequate. In various embodiments, chamber <NUM> may include multiple hydrogen outlet channels <NUM> and may include any number of channels placed at any location of chamber <NUM>.

<FIG> show an illustrative embodiment of chamber <NUM> forming a serpentine channel <NUM> and having an inlet <NUM> and an outlet <NUM>. Serpentine channel <NUM> may facilitate interaction of the hydrogen liquid carrier with a catalyst that may be deposited on the walls of serpentine channel <NUM>. In various embodiments, serpentine channel <NUM> may result in the flow of the hydrogen liquid carrier progressing through turns that may promote mixing of the carrier. Furthermore, serpentine channel <NUM> may be selected to have a large surface area to further promote catalyst interaction with the flow of the carrier. In various embodiments, serpentine channel <NUM> may include multiple hydrogen outlets <NUM> as shown in <FIG>. Designing chamber <NUM> as a serpentine channel <NUM> may be beneficial for applications where chamber <NUM> needs to occupy a small volume while maintaining a long chamber. Configuring chamber <NUM> as a serpentine channel <NUM> may be convenient for heat management of the chamber. For example, a heating or cooling module <NUM>, as shown in <FIG>, may be installed in proximity of at least one side of serpentine chamber <NUM> for efficient heat management. <FIG> shows an embodiment where heat managing units <NUM> and <NUM> may be installed on opposing sides of serpentine channel <NUM> with multiple hydrogen outlets <NUM> positioned as shown in <FIG>. In various embodiments, serpentine channel <NUM> may promote mixing as shown for example by streamlines <NUM> in <FIG>. Such streamlines may be generated, for example, by computational fluid dynamics simulations for the flow in serpentine chamber <NUM>.

<FIG> shows an example of serpentine chamber <NUM> with module <NUM>. In some embodiments, more than one reaction chamber may be used for hydrogen production from a hydrogen liquid carrier. In an example embodiment, two or more reaction chambers (e.g., a first and a second reaction chamber) with a heating and/or cooling module for each chamber may be used. In an example embodiment, the heating moduli of these chambers may be thermally connected, such that heat from the first reaction chamber may be transferred to the second reaction chamber.

<FIG> shows an illustrative embodiment of chamber <NUM> configured to include a loop channel <NUM>. In some embodiments, the hydrogen liquid carrier may enter loop channel <NUM> via an inlet <NUM>, with the flow controlled by an inflow valve <NUM>. In various embodiments, channel <NUM> may include a catalyst. In some cases, the catalyst may be deposited over the walls of channel <NUM>, and in some cases, the catalyst may be present within the channel as an insertable element. Similar to embodiments discussed above, the catalyst unit may be configured to be removable and may be secured to a portion of channel <NUM> by screws, bolts, clamps, clips, locking mechanisms, adhesive or any other means. In an illustrated embodiment, the catalyst may include multiple porous sheets positioned within the loop channel <NUM>. In various embodiments, walls of loop channel <NUM> may include roughness elements. In some embodiments, walls may have a roughness value between the range of <NUM> - <NUM> calculated as the roughness average. In some embodiments, walls may be coated by Ni, followed by deposition of a catalyst. In various embodiments, the catalyst may include any suitable catalyst for facilitating hydrogen production and may include transition metals, such as Fe, Co, Cu, Ni, Ru, Pt, alloys, and combinations thereof. While the present disclosure provides examples of exemplary roughness values, it should be noted that aspects of the disclosure in their broadest sense, are not limited to these particular values.

In various embodiments, an inflow of the hydrogen liquid carrier may be facilitated by a pump, as the pressure inside reaction chamber <NUM> may be higher than the pressure in the inflow valve. In some embodiments, the pressure in reaction chamber <NUM> may be reduced by releasing hydrogen via a hydrogen outflow <NUM>. In an illustrative embodiment, shown in <FIG>, chamber <NUM> may include a section <NUM> for storing hydrogen.

In various embodiments, the hydrogen liquid carrier may circulate within loop channel <NUM> through operation of a pump <NUM>, which may be operated at predetermined intervals and/or for a predetermined amount of time. In an example embodiment, the flow rate of the hydrogen liquid carrier and the time of circulation of the carrier within the chamber may be controlled by computing system <NUM>. In an example embodiment, chamber <NUM> may include a pressure sensor <NUM> that measures pressure (e.g., hydrogen pressure) within a chamber. In an example embodiment, data from pressure sensor <NUM> may be transmitted to computing system <NUM> for evaluating changes in pressure as a function of time, as shown for example by curve <NUM>. When pressure is substantially unchanged or constant (e.g., region <NUM> of curve <NUM>) no release (or generation) of hydrogen may be observed, which may indicate that the hydrogen liquid carrier may be depleted. The depleted (or spent) hydrogen liquid carrier may be discharged via an outlet <NUM> by opening an outflow valve <NUM>.

In some embodiments, the spent carrier may be discharged from chamber <NUM>, as the hydrogen liquid carrier flows into a chamber. In various embodiments, chamber <NUM> may also include an inlet <NUM> for flowing various chemical compounds or liquids into chamber <NUM>. In some embodiments, inlet <NUM> may be configured to flow water. For example, in some embodiments, water may be circulated in channel <NUM> for cleaning channel <NUM>.

In some embodiments, inflow <NUM> may allow a concentrated hydrogen liquid carrier to enter loop channel <NUM>, and water may be added via inflow <NUM>. During the circulation of the hydrogen liquid carrier within loop channel <NUM>, the concentrated hydrogen liquid carrier may be mixed with water to provide an aqueous solution of a hydrogen liquid carrier. During a process of discharging a spent carrier, the spent carrier may be released by opening an outflow valve, while, at the same time, adding more water into loop channel <NUM> via inflow <NUM>.

<FIG> illustrates a process <NUM> for operating loop channel <NUM> of chamber <NUM>. At step <NUM> of process <NUM> hydrogen outflow <NUM> may be opened allowing some of the hydrogen to be released from channel <NUM>; at step <NUM> inflow valve <NUM> may be opened allowing a hydrogen liquid carrier to enter channel <NUM>; at step <NUM> hydrogen valve <NUM> may be closed and inflow valve <NUM> may be closed, and pump starts cycling the hydrogen liquid carrier at step <NUM>. During the carrier cycling, the carrier is depleted releasing hydrogen and increasing pressure inside chamber <NUM>. At step <NUM>, when the hydrogen liquid carrier is partially or fully depleted (as can be, for example, tested by pressure sensor <NUM>), valve <NUM> may be opened allowing for the spent carrier to exit the channel <NUM>.

In various embodiments, system <NUM> may include more than one loop channel <NUM> as shown in <FIG>. For example, system <NUM> may include a fast and a slow loop channel. The fast loop channel may be similar to loop channel <NUM> and may be configured for releasing a large amount of hydrogen quickly. For example, the fast channel may be configured to circulate the hydrogen liquid carrier at a fast rate through the fast loop channel. The fast channel may not be configured to completely deplete the hydrogen liquid carrier, and a partially depleted hydrogen liquid carrier may flow to the slow channel. The slow channel, on the other hand, may be configured to completely deplete the hydrogen liquid carrier by allowing the carrier to release all of its contained hydrogen through a slow circulation process.

<FIG> shows an illustrative embodiment of chamber <NUM> configured in a form of a showerhead <NUM>. The hydrogen-based fluid may enter showerhead <NUM> via inlet <NUM>, pass through serpentine section <NUM> to reduce variation in flow velocity and pressure due to inflow conditions. After passing serpentine section <NUM>, the flow may enter a set of outflow channels <NUM>. Each outflow channel include a catalyst. In an illustrative embodiment the catalyst may be deposited on the walls of channels <NUM>. In various embodiments, the catalyst may also be presented in the serpentine section <NUM>. For example, the catalyst may be deposited on the walls forming serpentine section <NUM>. In various embodiments, outflow channels include hydrogen outlets <NUM> for releasing hydrogen from chamber <NUM>.

In various embodiments, the design of chamber <NUM> may include computational simulations to evaluate the efficiency of hydrogen release. For example, during computational simulation, various trajectories of liquid volumes within the flow of the hydrogen liquid carrier may be evaluated. For each trajectory, an effective time that describes the interaction of liquid volume with the catalyst may be estimated.

The foregoing description has been presented for purposes of illustration. It is not exhaustive and is not limited to precise forms or embodiments disclosed. Modifications and adaptations of the embodiments will be apparent from a consideration of the specification and practice of the disclosed embodiments. For example, while certain components have been described as being coupled to one another, such components may be integrated with one another or distributed in any suitable fashion.

Moreover, while illustrative embodiments have been described herein, the scope includes any and all embodiments having equivalent elements, modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations based on the present disclosure. The elements in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. Further, the steps of the disclosed methods can be modified in any manner, including reordering steps and/or inserting or deleting steps.

The features and advantages of the disclosure are apparent from the detailed specification, and thus, it is intended that the appended claims cover all systems and methods falling within the scope of the disclosure. As used herein, the indefinite articles "a" and "an" mean "one or more. " Similarly, the use of a plural term does not necessarily denote a plurality unless it is unambiguous in the given context. Words such as "and" or "or" mean "and/or" unless specifically directed otherwise. Further, since numerous modifications and variations will readily occur from studying the present disclosure, it is not desired to limit the disclosure to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure.

Claim 1:
A reaction chamber (<NUM>) for generating hydrogen gas using a hydrogen liquid carrier line, the reaction chamber comprising:
a channel (<NUM>) including a catalyst (403A, 403B) for causing the hydrogen gas to be produced from the hydrogen liquid carrier, the channel including an inlet end (<NUM>) for the hydrogen liquid carrier, an outlet end (<NUM>) for a spent carrier, and at least one mixing element to enhance mixing of the hydrogen liquid carrier;
a valve (<NUM>, <NUM>) for controlling a rate of flow of the hydrogen liquid carrier flowing through the channel;
a gas outlet (405A-405C) for evacuating the hydrogen gas generated in the channel; and
at least one processor (<NUM>) configured to receive at least one signal from a power consuming system indicating a demand for the hydrogen gas and to control the valve (<NUM>, <NUM>) to adjust the rate of flow of the hydrogen liquid carrier to meet the demand for the hydrogen gas.