Selective CO oxidation over a commercial PROX monolith catalyst for hydrogen fuel cell applications

Preferential oxidation (PROX) of CO over noble-metal-containing monolith catalysts is one of the most promising approaches for removing CO to generate low temperature fuel cell quality H₂. The monolith-supported washcoated catalyst comprising Cu and Fe promoted with Pt is highly effective in reducing the CO in practical reformates to less than 10 ppm over a broad range of feed compositions, inlet temperatures and turn down ratios. It is speculated that Pt dissociates the H₂ which then reduces the CuO to its active state. Pt may also act as a cocatalyst for CO adsorption with metal oxides supplying oxygen for PROX reaction. The catalytic system is operated adiabatically with an inlet temperature between roughly 65–120 °C reaching an exit temperature close to 150 °C with no evidence of reverse water gas shift or methanation. The goal was to find the proper operating conditions to achieve <10 ppm CO. Turn down ratios (varying space velocities) at a factor of 4–5 are routinely achieved up to at least 34,000 h⁻¹ with high steam levels of up to 45%. The wide operating window simplifies the control of the PROX reactor and improves the fuel processor’s performance for fast startup and shutdown and responses to transient loads. The catalyst also retains its performance after multiple start and stops modes of operation in reformate.     

Durability of solid oxide fuel cells using sulfur containing fuels

The usability of hydrogen and also carbon containing fuels is one of the important advantages of solid oxide fuel cells (SOFCs), which opens the possibility to use fuels derived from conventional sources such as natural gas and from renewable sources such as biogas. Impurities like sulfur compounds are critical in this respect. State-of-the-art Ni/YSZ SOFC anodes suffer from being rather sensitive towards sulfur impurities. In the current study, anode supported SOFCs with Ni/YSZ or Ni/ScYSZ anodes were exposed to H₂S in the ppm range both for short periods of 24 h and for a few hundred hours. In a fuel containing significant shares of methane, the reforming activities of the Ni/YSZ and Ni/ScYSZ anodes were severely poisoned already at low H₂S concentrations of ∼2 ppm H₂S. The poisoning effect on the cell voltage was reversible only to a certain degree after exposure of 500 h in the state-of-the-art cell, due to a loss of percolation of Ni particles in the Ni/YSZ anode layers closest to the electrolyte. Using SOFCs with Ni/ScYSZ anodes improved the H₂S tolerance considerably, even at larger H₂S concentrations of 10 and 20 ppm over a few hundred hours.     

The effect of H2S on the performance of Ni-YSZ anodes in solid oxide fuel cells

Biomass-derived fuel, e.g. biogas, is a potential fuel for solid oxide fuel cells (SOFCs). At operating temperature (∼850 °C) reforming of the carbon-containing biogas takes place over the Ni-containing anode. However, impurities in the biogas, e.g. H₂S, can poison both the reforming and the electrochemical activity of the anode.Tests of single anode-supported planar SOFCs were carried out in the presence of H₂S under current load at 850 °C. The cell voltage dropped as we periodically added 2-100 ppm H₂S to an H₂-containing fuel in 24 h intervals, but it regenerated to the initial value after we turned off the H₂S. Evaluation of the changes of the cell voltage suggests that saturation coverage was reached at approximately 40 ppm H₂S. A front-like movement of S-poisoning over the anode was seen by monitoring the in-plane voltage in the anode. Furthermore, impedance spectra showed that mainly the polarization resistance increased when adding H₂S. These changes in resistance were found to happen at 1212 Hz, which is related to reactions at the anode-electrolyte interface. These findings can be used to identify S-related effects on the performance, when an SOFC is fuelled with biogas or other fuels with H₂S impurities and thus help in the development of more sulfur tolerant SOFCs.     

H2 production from stable ethanol steam reforming over catalyst of NiO based on flowerlike CeO2 microspheres

Catalyst of nickle oxide based on flowerlike cerium microspheres with high dispersion was made to achieve simultaneous dehydrogenation of ethanol and water molecules on multi-active sites. XRD, 77 K N₂ adsorption and FESEM were applied to analyse and observe the catalyst's structure, porosity and morphology. This special morphology catalyst represented novel stability more than 600 h for hydrogen production at low temperature ethanol steam reforming. Ethanol-water mixtures could be converted into H₂ with average selectivity value of 61.5 mol.% and average ethanol conversion 95.0 mol.% at 350 °C, with GHSV∼1.0 × 10⁵ h⁻¹, low CO selectivity about average value of 2.1 mol.%, during 550 h reforming stability test. Catalytic parameters with respect to yield of H₂, activity, selectivity towards hydrogen production and stability with time on stream were determined.     

Deactivation of Pt/VC proton exchange membrane fuel cell cathodes by SO2, H2S and COS

Sulfur contaminants in air pose a threat to the successful operation of proton exchange membrane fuel cells (PEMFCs) via poisoning of the Pt-based cathodes. The deactivation behavior of commercial Pt on Vulcan carbon (Pt/VC) membrane electrode assemblies (MEAs) is determined when exposed to 1 ppm (dry) of SO₂, H₂S, or COS in air for 3, 12, and 24 h while held at a constant potential of 0.6 V. All the three sulfur compounds cause the same deactivation behavior in the fuel cell cathodes, and the polarization curves of the poisoned MEAs have the same decrease in performance. Sulfur coverages after multiple exposure times (3, 12, and 24 h) are determined by cyclic voltammetry (CV). As the exposure time to sulfur contaminants increases from 12 to 24 h, the sulfur coverage of the platinum saturates at 0.45. The sulfur is removed from the cathodes and their activity is partially restored both by cyclic voltammetry, as shown by others, and by successive polarization curves. Complete recovery of fuel cell performance is not achieved with either technique, suggesting that sulfur species permanently affect the surface of the catalyst.     

The effect of low concentrations of CO on H2 adsorption and activation on Pt/C. Part 1: In the absence of humidity

The presence of CO in the H₂-rich gas used as fuel for hydrogen fuel cells has a detrimental effect on PEMFC performance and durability at conventional operating conditions. This paper reports on an investigation of the effect of CO on H₂ activation on a fuel cell Pt/C catalyst close to typical PEMFC operating conditions using H₂-D₂ exchange as a probe reaction and to measure hydrogen surface coverage. While normally limited by equilibrium in the absence of impurities on Pt at typical fuel cell operating temperatures, the presence of ppm concentrations of CO increased the apparent activation energy (E_a) of H₂-D₂ exchange reaction (representing H₂ activation) from approximately 4.5-5.3 kcal mole⁻¹ (Bernasek and Somorjai (1975) [24], Montano et al. (2006) [25]) (in the absence of CO) to 19.3-19.7 kcal mole⁻¹ (in the presence of 10-70 ppm CO), similar to those reported by Montano et al. (2006) [25]. Calculations based on measurements indicate a CO surface coverage of approximately 0.55 ML at 80 °C in H₂ with 70 ppm CO, which coincide very well with surface science results reported by Longwitz et al. (2004) [5]. In addition, surface coverages of hydrogen in the presence of CO suggest a limiting effect on hydrogen spillover by CO. Regeneration of Pt/C at 80 °C in H₂ after CO exposure showed only a partial recovery of Pt sites. However, enough CO-free Pt sites existed to easily achieve equilibrium conversion for H₂-D₂ exchange. This paper establishes the baseline and methodology for a series of future studies where the additional effects of Nafion and humidity will be investigated.     

Modeling of a catalytic membrane reactor for CO removal from hydrogen streams – A theoretical study

Typical industrial hydrogen streams arising from reforming processes contain about 1% of carbon monoxide (CO). For fuel cell applications hydrogen should contain less than 10 ppm of CO, since it poisons the platinum catalysts in the electrodes. Traditionally, this is carried out through a selective oxidation reactor – PROX reactor. However, the parallel oxidation of hydrogen to water should be avoided. This work proposes the use of a catalytic membrane reactor (MR) whose design is based on a CO permselective membrane containing the selective catalyst loaded in the permeate side. It is considered plug-flow pattern and segregated feed of CO and oxygen. This strategy should improve the selective oxidation, as the permselective membrane enhances the CO/H₂ ratio at the catalyst surface.     

Investigations of a platinum-ruthenium/carbon nanotube catalyst formed by a two-step spontaneous deposition method

Platinum (Pt) is a popular catalyst for hydrogen oxidation on the anode side of solid polymer fuel cells (SPFC). It increases the electrode activity, which catalyzes the reaction of the fuel cell. There are two methods commonly used to produce hydrogen for SPFC: fuel reforming and methanol decomposition. Both of these methods produce carbon monoxide, which is considered to be a poison for SPFC because it deactivates Pt easily. Adding ruthenium (Ru) to a Pt catalyst is an efficient way to improve the inhibition of carbon monoxide (CO) formation and reduce the Pt loading requirement.This study introduces a method to synthesize a bimetal catalyst that is suitable for SPFC. To improve the electrocatalyst activity, a new process with two spontaneous deposition steps is adopted. In the first step, Ru is deposited on the wall of carbon nanotubes (CNTs) to obtain Ru/CNTs. Pt is then added in the second deposition step to form Pt-Ru/CNTs. The morphology and microstructure of catalysts are characterized with microscopes, and the performance of membrane electrode assembly is evaluated by cyclic voltammetry method. Experimental results have proved that even with a lower Pt loading, this home-brewed bimetal catalyst performs a compatible electrocatalytic activity, and is capable of resisting attack from CO when a syngas (H₂ + 20 ppm CO) is provided.     

The effect of H2S and CO mixtures on PEMFC performance

Proton exchange membrane fuel cells (PEMFCs) most likely will use reformed fuel as the primary source for the anode feed which always contains carbon dioxide (CO) and hydrogen sulfide (H₂S). Trace amount of CO and H₂S can cause considerable cell performance losses. A comparison between the effect of CO and that of H₂S on PEMFC performance was made in this paper. Under the same conditions, the H₂S poisoning rate is much higher than CO because of different adsorption intensity. When the fuel stream contains the gas mixture (25 ppm CO and 25 ppm H₂S), the fuel cell performance deteriorates more quickly than 50 ppm CO but slowly than 50 ppm H₂S and can be only partially recovered by reintroducing neat H₂. The resulting effects of the mixtures can be divided into two parts roughly: during the inception phase, the cell voltage drops quickly and the actual values of anode overvoltage are bigger than the corresponding calculated values; then the deterioration rate of the cell performance decreases gradually.     

n-C4H10 autothermal reforming over MgO-supported base metal catalysts

We report n-C₄H₁₀ autothermal reforming over MgO-supported base metal catalysts at 723 K. Catalytic performance was investigated not only after H₂ treatment at 1073 K (reductive treatment) but also after subsequent O₂/Ar treatment at the reaction temperature (oxidative treatment) to mimic the shutdown and startup of a domestic fuel cell system. After reductive treatment, both Ni/MgO and Co/MgO exhibited high n-C₄H₁₀ conversion and hydrogen formation activity; the stability of Ni/MgO was better than that of Co/MgO. The reaction route was investigated by measuring activity at various contact times. The results revealed that n-C₄H₁₀ autothermal reforming over Ni/MgO is a multi-step reaction composed of combustion, steam reforming, water gas shift reaction, and methanation. In contrast, Cu/MgO and Fe/MgO did not show reforming activity but cracking and combustion of n-C₄H₁₀. Ni/MgO and Co/MgO catalyzed H₂ formation even after the oxidative treatment. However, the initial activity of Co/MgO after the oxidative treatment was lower than that after the reductive treatment and a decrease in H₂ formation rate was again observed after 6 h in Co/MgO, similar to the measurements after the reductive treatment.     

Design of compact methanol reformer for hydrogen with low CO for the fuel cell power generation

The effect of the heat transfer area and the thermal conductivity of the reactor materials are evaluated with three identical structured reactors having multiple columned-catalyst bed and using three different reactor materials, aluminum alloy, brass and stainless steel. A series of compact methanol reformers are then designed and fabricated with the use of large reactor surface area in catalyst beds and high heat transfer constant to produce hydrogen fuel with 2–4 ppm of CO for the fuel cell (FC) power generation. The same design principle is successfully used for easy scale up of the reactor capacity from 250 L/h to 10,000 L/h. This low CO hydrogen (68–70%) used as the fuel for the fuel cell power generation provides a very competitive cost of hydrogen and electric power, $0.20–0.23/m³ of H₂ and $0.196/KWh, respectively.     

Aqueous-phase reforming of n-BuOH over Ni/Al2O3 and Ni/CeO2 catalysts

The aqueous-phase reforming (APR) of n-butanol (n-BuOH) over Ni(20 wt%) loaded Al₂O₃ and CeO₂ catalysts has been studied in this paper. Over 100 h of run time, the Ni/Al₂O₃ catalyst showed significant deactivation compared to the Ni/CeO₂ catalyst, both in terms of production rates and the selectivity to H₂ and CO₂. The Ni/CeO₂ catalyst demonstrated higher selectivity for H₂ and CO₂, lower selectivity to alkanes, and a lower amount of C in the liquid phase compared to the Ni/Al₂O₃ sample. For the Ni/Al₂O₃ catalyst, the selectivity to CO increased with temperature, while the Ni/CeO₂ catalyst produced no CO. For the Ni/CeO₂ catalyst, the activation energies for H₂ and CO₂ production were 146 and 169 kJ mol⁻¹, while for the Ni/Al₂O₃ catalyst these activation energies were 158 and 175 kJ mol⁻¹, respectively. The difference of the active metal dispersion on Al₂O₃ and CeO₂ supports, as measured from H₂-pulse chemisorption was not significant. This indicates deposition of carbon on the catalyst as a likely cause of lower activity of the Ni/Al₂O₃ catalyst. It is unlikely that carbon would build up on the Ni/CeO₂ catalyst due to higher oxygen mobility in the Ni doped non-stoichiometric CeO₂ lattice. Based on the products formed, the proposed primary reaction pathway is the dehydrogenation of n-BuOH to butaldehyde followed by decarbonylation to propane. The propane then partially breaks down to hydrogen and carbon monoxide through steam reforming, while CO converts to CO₂ mostly through water gas shift. Ethane and methane are formed via Fischer-Tropsch reactions of CO/CO₂ with H₂.     

High yield hydrogen production from low CO selectivity ethanol steam reforming over modified Ni/Y2O3 catalysts at low temperature for fuel cell application

Ethanol–water mixtures were converted directly into H₂ with 67.6% yield and >98% conversion by catalytic steam reforming at 350 °C over modified Ni/Y₂O₃ catalysts heat treated at 500 °C. XRD was used to test the structure and calculate the grain sizes of the samples with different scan rates. The initial reaction kinetics of ethanol over modified and unmodified Ni/Y₂O₃ catalysts were studied by steady state reaction and a first-order reaction with respect to ethanol was found. TPD was used to analyze mechanism of ethanol desorption over Ni/Y₂O₃ catalyst. Rapid vaporization, efficiency tube reactor and catalyst were used so that homogeneous reactions producing carbon, acetaldehyde, and carbon monoxide could be minimized. And even no CO detective measured during the first 49 h reforming test on the modified catalyst Ni/Y₂O₃. This process has great potential for low cost H₂ generation in fuel cells for small portable applications where liquid fuel storage is essential and where systems must be small, simple, and robust.     

Selective CO oxidation with real methanol reformate over monolithic Pt group catalysts: PEMFC applications

Alumina supported Pt group metal monolithic catalysts were investigated for selective oxidation of CO in hydrogen-rich methanol reforming gas for proton exchange membrane fuel cell (PEMFC) applications. The results are described and discussed in the present paper and show that Pt/γ_Al2O3$\mathrm{Pt}/\gamma {\mathrm{Al}}_2{\mathrm{O}}_3$ was the most promising candidate to selectively oxidize CO from an amount of about 1 vol% to less than 100 ppm. We have investigated the effect of the O₂ to CO feed ratio, the feed concentration of CO, the presence of H₂O and/or CO₂, and the space velocity on the activity, selectivity and stability of Pt/Al₂O₃ monolithic catalysts. Afterwards, the Pt/Al₂O₃ catalyst was scaled up and applied in 5 kW hydrogen producing systems based on methanol steam reforming and autothermal reforming. The hydrogen produced was then used as fuel for an integrated PEMFC.     

K (Na)-promoted Ni,Al layered double hydroxide catalysts for the steam reforming of methanol

Production of hydrogen by methanol steam reforming has been studied over a series of Ni/Al layered double hydroxide catalysts prepared by the co-precipitation method, with the aim to develop a stable catalyst that can be used in a membrane-joint performer at temperatures greater than 300 °C. H₂, CO and CO₂ are generally the major products together with trace amounts of CH₄. The presence of potassium and/or sodium cations was found to improve the activity of methanol conversion. The selectivity for CO₂ rather than CO was better with K ions than Na ions, especially at higher temperatures (e.g. 390–400 °C). Methanol steam reforming over a K-promoted Ni/Al layered double hydroxide catalyst resulted in better activity and similar stability compared to a commercial Cu catalyst.     

Microfibrous structured catalytic packings for miniature methanol fuel processor: Methanol steam reforming and CO preferential oxidation

The microfibrous structured catalytic packings for miniature fuel processor consisting of a methanol steam reformer and a subsequent CO cleanup train has been investigated experimentally. A highly void and tailorable sinter-locked microfibrous carrier consisting of 3.5 vol% 8 μm diameter Ni-fibers is used to entrap 35 vol% 150-250 μm catalyst particulates for both methanol steam reforming (MSR) and CO preferential oxidation (PROX). We demonstrate a microfibrous entrapped Pd-ZnO/Al₂O₃ catalyst packings for high efficiency hydrogen production by the MSR reaction. The use of microfibrous entrapment technology significantly enhances the catalyst utilization efficiency by a 4-fold improvement of the weight hourly space velocity (WHSV), compared to the single Pd-ZnO/Al₂O₃ particulates as keeping the methanol conversion at >98%. The microfibrous entrapped Pt-Co/Al₂O₃ catalyst packings can drive the CO from 2% down to <50 ppm at 150 °C with O₂/CO ratio of 1 using a gas hourly space velocity (GHSV) of 32,000 h⁻¹. Finally, a prototype fuel processor system integrating MSR reformer and CO PROX train is demonstrated as three reactors in series. Such test rig is capable of producing roughly 1700 standard cubic centimeter per minute (sccm) PEMFC-grade H₂ (equivalent to ∼163 W of electric power) in a longer-term test, in which the MSR reactor is operated at 300 °C using a methanol/water (1/1.1, mole) mixture WHSV of 9 h⁻¹ and CO PROX reactors at 150 °C using an O₂/CO molar ratio of 1.3, respectively. In the test of this prototype system, MSR reactor delivers >97% methanol conversion throughout the entire 1200-h test; the CO cleanup train placed in line after 800-h MSR illustrates the capability to decrease the CO concentration from ∼3.5% to ∼1% at PROX-1 and then to less than 20 ppm at PROX-2 until to the end of test.     

Hydrogen production by sorption enhanced steam reforming of oxygenated hydrocarbons (ethanol, glycerol, n-butanol and methanol): Thermodynamic modelling

Thermodynamic analysis of steam reforming of different oxygenated hydrocarbons (ethanol, glycerol, n-butanol and methanol) with and without CaO as CO₂ sorbent is carried out to determine favorable operating conditions to produce high-quality H₂ gas. The results indicate that the sorption enhanced steam reforming (SESR) is a fuel flexible and effective process to produce high-purity H₂ with low contents of CO, CO₂ and CH₄ in the temperature range of 723-873 K. In addition, the separation of CO₂ from the gas phase greatly inhibits carbon deposition at low and moderate temperatures. For all the oxygenated hydrocarbons investigated in this work, thermodynamic predictions indicate that high-purity hydrogen with CO content within 20 ppm required for proton exchange membrane fuel cell (PEMFC) applications can be directly produced by a single-step SESR process in the temperature range of 723-773 K at pressures of 3-5 atm. Thus, further processes involving water-gas shift (WGS) and preferential CO oxidation (COPROX) reactors are not necessary. In the case of ethanol and methanol, the theoretical findings of the present analysis are corroborated by experimental results from literature. In the other cases, the results could provide an indication of the starting point for experimental research. At P = 5 atm and T = 773 K, it is possible to obtain H₂ at concentrations over 97 mol% along with CO content around 10 ppm and a thermal efficiency greater than 76%. In order to achieve such a reformate composition, the optimized steam-to-fuel molar ratios are 6:1, 9:1, 12:1 and 4:1 for ethanol, glycerol, n-butanol and methanol, respectively, with CaO in the stoichiometric ratio to carbon atom.     

Y-doped SrTiO3 based sulfur tolerant anode for solid oxide fuel cells

A solid oxide fuel cell (SOFC) anode with high sulfur tolerance was developed starting from a Y-doped SrTiO₃ (SYTO)-yttria stabilized zirconia (YSZ) porous electrode backbone, and infiltrated with nano-sized catalytic ceria and Ru. The size of the infiltrated particles on the SYTO-YSZ pore walls was 30–200 nm, and both infiltrated materials improved the performance of the SYTO-YSZ anode significantly. The infiltrated ceria covered most of the surface of the SYTO-YSZ pore walls, while Ru was dispersed as individual nano-particles. The performance and sulfur tolerance of a cathode supported cell with ceria- and Ru-infiltrated SYTO-YSZ anode was examined in humidified H₂ mixed with H₂S. The anode showed high sulfur tolerance in 10–40 ppm H₂S, and the cell exhibited a constant maximum power density 470 mW cm⁻² at 10 ppm H₂S, at 1073 K. At an applied current density 0.5 A cm⁻², the addition of 10 ppm H₂S to the H₂ fuel dropped the cell voltage slightly, from 0.79 to 0.78 V, but completely recovered quickly after the H₂S was stopped. The ceria- and Ru-infiltrated SYTO-YSZ anode showed much higher sulfur tolerance than conventional Ni-YSZ anodes.