Fuel processor for fuel cell systems

1 . A fuel processor assembly for producing a hydrogen rich stream for a fuel cell comprising:

a reformer;

a vaporizer adjacent the reformer;

a heat transfer block around at least a portion of the reformer and the vaporizer; and

at least one heating element coupled to the heat transfer block for providing heat to the block during start up.

2 . A fuel processor as recited in claim 1 , further comprising a burner adjacent the heat transfer block for providing heat to the block during normal operation.

3 . A fuel processor as recited in claim 1 , wherein the reformer includes a plurality of tubes held in place between an inlet header and an outlet header.

4 . A fuel processor as recited in claim 3 , wherein each tube is between 1 mm and 5 mm interior diameter and has an inner surface at least partially coated with catalyst.

5 . A fuel processor as recited in claim 1 , wherein the vaporizer is selected from the group consisting of: a coil that wraps around the reformer; vaporizer tubes held adjacent to the reformer, wherein the reformer has tubes and the vaporizer and reformer tubes are fixed between headers; at least one vaporizer tube secured within heat exchanging fins; and combinations thereof.

6 . A fuel processor as recited in claim 1 , wherein the heat transfer block is a metal cast onto the reformer and vaporizer, the metal being selected from the group consisting of aluminum, copper, steel, titanium and combinations and alloys thereof.

7 . A fuel processor as recited in claim 1 , further comprising a temperature sensor coupled to the heat transfer block.

8 . A fuel processor as recited in claim 1 , further comprising a hydrogen purification membrane coupled to an output of the reformer.

9 . A fuel processor as recited in claim 1 , wherein the reformer has tubes that are wash-coated with a catalyst.

10 . A method for cold starting a fuel processor for a fuel cell comprising the steps of:

activating a block heater to elevate a temperature of a heat transfer block, wherein a vaporizer and reformer are located at least partially within the heat transfer block; and

monitoring the temperature of the heat transfer block so that the block heater is turned off near a minimum operating temperature of the reformer.

11 . A method as recited in claim 10 , further comprising the steps of:

activating a pump to urge fuel through the vaporizer and reformer to generate a hydrogen output stream; and

using a burner to continually heat the heat transfer block, wherein a fuel supply for the burner is a portion of the hydrogen output stream.

12 . A method of building a fuel processor comprising the steps of:

providing a reformer;

coupling a vaporizer to the reformer so that an outlet of the vaporizer is in fluid communication with an inlet of the reformer;

casting a heat transfer element onto at least a portion of the vaporizer and reformer; and

applying a heating element to the heat transfer element, wherein the heating element is only utilized during cold starts.

13 . A method as recited in claim 12 , wherein the reformer, vaporizer and heat transfer element are located with a housing that defines a hot zone.

14 . A method as recited in claim 12 , further comprising the step of pumping fuel from a fuel supply into the vaporizer.

15 . A method as recited in claim 12 , wherein the heat transfer element is a metal block cast onto the reformer and vaporizer, the block defining at least one hole to retain the heating element.