WATER-GAS SHIFT WITH INTEGRATED HYDROGEN SEPARATION PROCESS

Optimization of the water-gas shift (WGS) reaction system for hydrogen production for fuel cells is of particular interest to the energy industry. To this end, it is desirable to couple the WGS reaction to hydrogen separation using a semi-permeable membrane, with both processes carried out at high temperatures to improve reaction kinetics and permeation. Reduced equilibrium conversion of the WGS reaction at high temperatures is overcome by product H{sub 2} removal via the membrane. This project involves 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 will be examined in the project. The first-year screening studies of WGS catalysts identified Cu-ceria as the most promising high-temperature 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}, and were thus eliminated from further consideration. 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. Several catalyst formulations were prepared, characterized and tested in the first year of study. Details from the catalyst development and testing work were given in our first annual technical report. Hydrogen permeation through Pd and Pd-alloy foils was investigated in a small membrane reactor constructed during the first year of the project. The effect of temperature on the hydrogen flux through pure Pd, Pd{sub 60}Cu{sub 40} and Pd{sub 75}Ag{sub 25} alloy membranes, each 25 {micro}m thick, was evaluated in the temperature range from 250 C to 500 C at upstream pressure of 4.4 atm and permeate hydrogen pressure of 1 atm. Flux decay was observed for the Pd-Cu membrane above 500 C. From 350-450 C, an average hydrogen flux value of 0.2 mol H{sub 2}/m{sup 2}/s was measured over this Pd-alloy membrane. These results are in good agreement with literature data. In this year's report, we discuss reaction rate measurements, optimization of catalyst kinetics by proper choice of dopant oxide (lanthana) in ceria, long-term stability studies, and H{sub 2} permeation data collected with unsupported flat, 10 {micro}m-thick Pd-Cu membranes over a wide temperature window and in various gas mixtures. The high-temperature shift catalyst composition was further improved, by proper selection of dopant type and amount. The formulation 10 at%Cu-Ce(30 at%La)Ox was the best; this was selected for further kinetic studies. WGS reaction rates were measured in a simulated coal-gas mixture. The stability of catalyst performance was examined in 40-hr long tests. A series of hydrogen permeation tests were conducted in a small flat-membrane reactor using the 10 m{micro}-thick Pd-Cu membranes. Small inhibitory effects of CO and CO{sub 2} were found at temperatures above 350 C, while H{sub 2}O vapor had no effect on hydrogen permeation. No carbon deposition took place during many hours of membrane operation. The reaction extent on the blank (catalyst-free) membrane was also negligible. A larger flat-membrane reactor will be used next year with the catalyst wash coated on screens close coupled with the Pd-Cu membrane