Condenser/separator and method

1. A condenser for separating a fluid mixture into a condensed liquid and a non-condensed gas comprising:

a vertical inlet manifold to receive the gas mixture;

a vertical outlet manifold;

a gas flow path fluidly connected to the inlet manifold and the outlet manifold to direct a gas flow from the inlet manifold to the outlet manifold in heat exchange relation to a cooling fluid flow;

a liquid flow path fluidly connected to the inlet manifold and the outlet manifold to direct a liquid flow in multiple passes between the inlet manifold and the outlet manifold in heat exchange relation to the cooling fluid flow;

a gas outlet fluidly connected to the outlet manifold to permit the non-condensed gas to exit the condenser; and

a liquid outlet fluidly connected to one of the manifolds to permit the condensed liquid to exit the condenser.

2. The condenser of claim 1 wherein the liquid outlet is a stand pipe having a vertical height that defines a liquid level in both of the manifolds.

3. The condenser of claim 1 wherein the liquid outlet is located at the outlet manifold.

4. The condenser of claim 1 wherein the vertical inlet manifold receives the gas mixture and has an upper portion and a lower portion, the vertical outlet manifold receives the condensed liquid and the non-condensed gas and has an upper portion and a lower portion, and a liquid level separates the upper portion from the lower portion in each of the manifolds.

5. The condenser of claim 1 further comprising a baffle with an opening defining a gas bleed located in a lower portion of the inlet manifold.

6. The condenser of claim 1 wherein the gas flow path comprises a first plurality of tubes and the liquid flow path comprises a second plurality of tubes located below the first plurality of tubes.

7. The condenser of claim 6 wherein the liquid flow path is divided by at least one baffle in one of the manifolds to provide a plurality of passes.

8. The condenser of claim 7 further comprising another baffle with an opening defining a gas bleed located in a lower portion of the inlet manifold.

9. A cathode exhaust gas condenser for use in a fuel cell system for separating a cathode exhaust into a condensed liquid and a non-condensed gas comprising:

a vertical inlet manifold to receive the cathode exhaust;

a vertical outlet manifold;

a cathode exhaust flow path fluidly connected to the inlet manifold and the outlet manifold to direct a gas flow from the inlet manifold to the outlet manifold in heat exchange relation to a cooling fluid flow;

a liquid flow path fluidly connected to the inlet manifold and the outlet manifold to direct a liquid flow in multiple passes between the inlet manifold and the outlet manifold in heat exchange relation to the cooling fluid flow;

a gas outlet fluidly connected to the outlet manifold to permit the non-condensed gas to exit the condenser; and

a liquid outlet fluidly connected to one of the manifolds to permit the condensed liquid to exit the condenser.

10. The condenser of claim 9 wherein the liquid outlet is a stand pipe having a vertical height that defines a liquid level in both of the manifolds.

11. The condenser of claim 9 wherein the liquid outlet is located at the outlet manifold.

12. The condenser of claim 9 wherein the vertical inlet manifold receives the gas mixture and has an upper portion and a lower portion, the vertical outlet manifold receives the condensed liquid and the non-condensed gas and has an upper portion and a lower portion, and a liquid level separates the upper portion from the lower portion in each of the manifolds.

13. The condenser of claim 9 further comprising a baffle with an opening defining a gas bleed located in the lower portion of an inlet manifold.

14. The condenser of claim 9 wherein the gas flow path comprises a first plurality of tubes and the liquid flow path comprises a second plurality of tubes located below the first plurality of tubes.

15. The condenser of claim 14 wherein the liquid flow path is divided by at least one baffle in one of the manifolds to provide a plurality of passes.

16. The condenser of claim 15 further comprising another baffle with an opening defining a gas bleed located in the lower portion of an inlet manifold.

17. A condenser for separating a fluid mixture into a condensed liquid and a non-condensed gas comprising:

a vertical inlet manifold to receive the gas mixture and having an upper portion and a lower portion;

a vertical outlet manifold to receive the condensed liquid and the non-condensed gas and having an upper portion and a lower portion;

a liquid level separating the upper portion from the lower portion in each of the manifolds;

a gas flow path fluidly connected to the inlet manifold and the outlet manifold to direct a gas flow from the inlet manifold to the outlet manifold in heat exchange relation to a cooling fluid flow;

a liquid flow path fluidly connected to the inlet manifold and the outlet manifold to direct a liquid flow from the inlet manifold to the outlet manifold in heat exchange relation to the cooling fluid flow;

a gas outlet fluidly connected to the gas flow path to permit the non-condensed gas to exit the condenser; and

a liquid outlet fluidly connected to the liquid flow path to permit the condensed liquid to exit the condenser.

18. The condenser of claim 17 wherein the liquid outlet comprises a stand pipe, the vertical location of the liquid level being defined by the vertical height of the stand pipe.

19. The condenser of claim 17 wherein the liquid outlet is located at the outlet manifold.

20. The condenser of claim 17 wherein the liquid flow path comprises multiple passes.

21. The condenser of claim 20 further comprising a baffle with an opening defining a gas bleed located in the lower portion of the inlet manifold.

22. The condenser of claim 17 wherein the gas flow path comprises a first plurality of tubes and the liquid flow path comprises a second plurality of tubes located below the first plurality of tubes.

23. The condenser of claim 22 wherein the liquid flow path is divided by at least one baffle in one of the manifolds to provide a plurality of passes.

24. The condenser of claim 23 further comprising another baffle with an opening defining a gas bleed located in the lower portion of the inlet manifold.

25. A cathode exhaust condenser for use in a fuel cell system for separating a cathode exhaust into a condensed liquid and a non-condensed gas comprising:

a vertical inlet manifold to receive the cathode exhaust and having an upper portion and a lower portion;

a vertical outlet manifold to receive the condensed liquid and the non-condensed gas and having an upper portion and a lower portion;

a liquid level separating the upper portion from the lower portion in each of the manifolds;

a gas flow path fluidly connected to the inlet manifold and the outlet manifold to direct a gas flow from the inlet manifold to the outlet manifold in heat exchange relation to a cooling fluid flow;

a liquid flow path fluidly connected to the inlet manifold and the outlet manifold to direct a liquid flow from the inlet manifold to the outlet manifold in heat exchange relation to the cooling fluid flow;

a gas outlet fluidly connected to the gas flow path to permit the non-condensed gas to exit the condenser; and

a liquid outlet fluidly connected to the liquid flow path to permit the condensed liquid to exit the condenser.

26. The condenser of claim 25 wherein the liquid outlet comprises a stand pipe, the vertical location of the liquid level being defined by the vertical height of the stand pipe.

27. The condenser of claim 25 wherein the liquid outlet is located at the outlet manifold.

28. The condenser of claim 25 wherein the liquid flow path comprises multiple passes.

29. The condenser of claim 28 further comprising a baffle with an opening defining a gas bleed located in the lower portion of the inlet manifold.

30. The condenser of claim 25 wherein the gas flow path comprises a first plurality of tubes and the liquid flow path comprises a second plurality of tubes located below the first plurality of tubes.

31. The condenser of claim 30 wherein the liquid flow path is divided by at least one baffle in one of the manifolds to provide a plurality of passes.

32. The condenser of claim 31 further comprising another baffle with an opening defining a gas bleed located in the lower portion of the inlet manifold.

33. A method for separating a fluid mixture into a condensed liquid and a non-condensed gas in a condenser, the method comprising the steps of:

flowing the fluid mixture into an inlet manifold;

separating the fluid mixture into a gas flow and a liquid flow in the inlet manifold;

cooling the liquid flow by flowing the liquid flow through a liquid flow path to an outlet manifold;

condensing at least a portion of the gas flow into condensed liquid by flowing the gas flow through a gas flow path to the outlet manifold;

again separating condensed liquid from non-condensed gas in the outlet manifold;

directing the non-condensed gas out of the condenser through a gas outlet; and

directing the condensed liquid out of the condenser through a liquid outlet.

34. The method of claim 33 further comprising, prior to directing the condensed liquid through the liquid outlet, the step of flowing the condensed liquid through an additional pass extending between the inlet manifold and the outlet manifold.