WATER-GAS SHIFT WITH INTEGRATED HYDROGEN SEPARATION PROCESS

This project involved fundamental research and development of novel cerium oxide-based catalysts for the water-gas-shift reaction and the integration of these catalysts with Pd-alloy H{sub 2} -separation membranes supplying high purity hydrogen for fuel cell use. Conditions matching the requirements of coal gasifier-exit gas streams were examined in the project. Cu-cerium oxide was identified as the most promising high-temperature water-gas shift catalyst for integration with H{sub 2}-selective membranes. Formulations containing iron oxide were found to deactivate in the presence of CO{sub 2}. Cu-containing ceria catalysts, on the other hand, showed high stability in CO{sub 2}-rich gases. This type gas will be present over much of the catalyst, as the membrane removes the hydrogen produced from the shift reaction. The high-temperature shift catalyst composition was optimized by proper selection of dopant type and amount in ceria. The formulation 10at%Cu-Ce(30at%La)O{sub x} showed the best performance, and was selected for further kinetic studies. WGS reaction rates were measured in a simulated coal-gas mixture. The apparent activation energy, measured over aged catalysts, was equal to 70.2 kJ/mol. Reaction orders in CO, H{sub 2}O, CO{sub 2} and H{sub 2} were found to be 0.8, 0.2, -0.3, and -0.3, respectively. This shows that H{sub 2}O has very little effect on the reaction rate, and that both CO{sub 2} and H{sub 2} weakly inhibit the reaction. Good stability of catalyst performance was found in 40-hr long tests. A flat (38 cm{sup 2}) Pd-Cu alloy membrane reactor was used with the catalyst washcoated on oxidized aluminum screens close coupled with the membrane. To achieve higher loadings, catalyst granules were layered on the membrane itself to test the combined HTS activity/ H{sub 2} -separation efficiency of the composite. Simulated coal gas mixtures were used and the effect of membrane on the conversion of CO over the catalyst was evidenced at high space velocities. Equilibrium CO conversion at 400 C was measured at a space velocity of 30,000 h{sup -1} with the 10{micro}m- thick Pd{sub 60}Cu{sub 40} membrane operating under a pressure differential of 100 psi. No carbon deposition took place during operation. The performance of the coupled Cu-ceria catalyst/membrane system at 400 C was stable in {approx} 30 h of continuous operation. The overall conclusion from this project is that Cu-doped ceria catalysts are suitable for use in high-temperature water-gas shift membrane reactors. CO{sub 2}-rich operation does not affect the catalyst activity or stability; neither does it affect hydrogen permeation through the Pd-Cu membrane. Operation in the temperature range of 400-430 C is recommended