Background In order to use hydrocarbon fuels in proton-exchange-membrane (PEM) fuel cell systems, fuel (e.g., gasoline or natural gas) must first be converted into a hydrogen-rich gas with little or no carbon monoxide (CO). Fuel processors based on multiple catalytic stages are being developed for this application. Synthesis Gas ConversionIn the first stage the hydrocarbon fuel is converted (reformed) to a synthesis gas (hydrogen and carbon monoxide) with a CO content of about 10-15 mol%.
Water Gas Shift (WGS) ReactionThe second stage is the water gas shift (WGS) reaction, which converts carbon monoxide to carbon dioxide while increasing the hydrogen content (CO + H2O " CO2+ H2). This reaction is generally performed in the temperature range of 250 to 400°C.
After the WGS stage, the CO content in the gas is between 0.5 and 1 mol%.
Clean Up StageThe final CO clean-up stage in a fuel processor involves either preferential oxidation of CO to CO2 by addition of air or collection of hydrogen using a hydrogen permeable membrane.
In traditional WGS fuel processors the reaction is carried out with two catalytic stages: relatively inactive iron-chrome catalysts running at higher temperatures in the first and active but temperature-limited copper-based catalysts in the second.
Pyrophoric Copper Based CatalystsA critical issue is that copper-based catalysts are pyrophoric and must be protected from air and condensed water during start-up and shut-down of the fuel processor. No single catalyst material has been available that provides the desired attributes of high activity and stability over the entire temperature range of interest - until now!
Water Gas Shift CatalystsOur WGS catalysts, based on nano-particle ceria-based mixed oxide supports with highly dispersed precious metals, provide a technically viable and cost-effective alternative for WGS catalysts used in fuel processors. Our catalysts are highly active above 250°C and are non-pyrophoric. Furthermore, these catalysts can be washcoated onto monolithic (honeycomb or foamed ceramic) supports so that small size can be maintained and precious metal utilization maximized.
Applications· Monolithic WGS reactors for PEM fuel cell systems
· Micro-channel WGS reactors for PEM fuel cell systems
· WGS membrane reactors for PEM fuel cell systems
Benefits· Pt/ceria catalysts are non-pyrophoric and provide high activity at temperatures above 250ºC (see Figures 1 and 2) for excellent start up, operating and shut down performance
· Pt/ceria catalysts can be regenerated by annealing in air (see Figure 3) for long life cycles
· Catalysts can be deposited onto monoliths, using low-cost, high-volume methods that are well established for automotive catalytic converters (see Figure 5)
· Less than six grams of precious metal will be required for a WGS monolith sized for a 50-kilowatt fuel processor based upon kinetics models