Patent ID: 7922781

Claim:
A method for generating hydrogen in a hydrogen membrane reactor having a combustion chamber defined by a bottom plate and a separation plate and a reaction chamber defined by a top plate and the separation plate, the combustion chamber in a fluid connection with and a heat exchange relationship with the reaction chamber, the combustion chamber including a combustion catalyst, the reaction chamber including a separation membrane defining a reaction zone and an exhaust zone in the reaction chamber, the combustion chamber comprising a plurality of combustion channels defined by a first set of spaced apart fins extending from the separation plate to and in contact with the bottom plate, the reaction zone comprising a plurality of reaction channels defined by a second set of spaced apart fins extending from the separation plate to and in contact with the separation membrane, the reaction zone including a reaction catalyst, the reaction catalyst having a reaction catalyst light-off temperature, the combustion catalyst light off temperature being lower than the reaction catalyst light off temperature, the method comprising: a. flowing stored hydrogen into the combustion chamber at a combustion catalyst light off temperature for the stored hydrogen, the combustion of the stored hydrogen generating first combustion product gases; b. replacing the flowing stored hydrogen into the combustion chamber with a combustible fuel different from the stored hydrogen at approximately a time when the temperature of the combustion catalyst reaches a combustion catalyst light-off temperature for the combustible fuel and continuing combustion to enable the temperature of the reaction catalyst to reach the reaction catalyst light off temperature, the combustion of the combustible fuel generating second combustion byproduct gases; c. flowing a hydrogen-producing hydrocarbon fuel other than alcohol in the reaction zone to contact the reaction catalyst at the reaction catalyst light off temperature in a range of about 550 C. to about 650 C. to produce a reaction zone hydrogen gas mixture comprising hydrogen gas and reaction tail gases, wherein flowing the hydrocarbon fuel in the reaction zone further comprises: c1. preheating water to at least about the boiling point of the hydrocarbon fuel to produce water vapor prior to contacting the water vapor with the hydrocarbon fuel; c2. contacting the water vapor with the hydrocarbon fuel in the reaction zone whereby said contacting reduces carbon formation in the reaction chamber; d. separating the hydrogen gas from the reaction zone hydrogen gas mixture through the hydrogen separation membrane, said hydrogen gas accumulated into the exhaust zone of the reactor chamber; and e. collecting the hydrogen gas from the exhaust zone of the reaction chamber.