WO2005068077A1 - Catalyst for the conversion of carbon monoxide - Google Patents

Catalyst for the conversion of carbon monoxide Download PDF

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Publication number
WO2005068077A1
WO2005068077A1 PCT/US2004/036299 US2004036299W WO2005068077A1 WO 2005068077 A1 WO2005068077 A1 WO 2005068077A1 US 2004036299 W US2004036299 W US 2004036299W WO 2005068077 A1 WO2005068077 A1 WO 2005068077A1
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Prior art keywords
catalyst
metal
support
ruthenium
group
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PCT/US2004/036299
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French (fr)
Inventor
Takeda Hiroshi
Troy Walsh
Jon Wagner
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Sued Chemie Inc
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Sued Chemie Inc
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Priority to EP04796883A priority Critical patent/EP1694441B1/en
Priority to CA002549133A priority patent/CA2549133A1/en
Priority to JP2006545629A priority patent/JP2007520333A/en
Priority to AT04796883T priority patent/ATE525128T1/en
Publication of WO2005068077A1 publication Critical patent/WO2005068077A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
    • B01J29/10—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing iron group metals, noble metals or copper
    • B01J29/12—Noble metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
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    • B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
    • B01J21/12—Silica and alumina
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    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
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    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
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    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
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    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
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    • B01J29/00—Catalysts comprising molecular sieves
    • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
    • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
    • B01J29/061—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof containing metallic elements added to the zeolite
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    • B01J29/18—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the mordenite type
    • B01J29/20—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the mordenite type containing iron group metals, noble metals or copper
    • B01J29/22—Noble metals
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    • B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
    • B01J29/72—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 containing iron group metals, noble metals or copper
    • B01J29/74—Noble metals
    • B01J29/7415—Zeolite Beta
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/02—Impregnation, coating or precipitation
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen; Reversible storage of hydrogen
    • C01B3/02—Production of hydrogen; Production of gaseous mixtures containing hydrogen
    • C01B3/06—Production of hydrogen; Production of gaseous mixtures containing hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen with inorganic reducing agents
    • C01B3/12—Production of hydrogen; Production of gaseous mixtures containing hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen with inorganic reducing agents by reaction of water vapour with carbon monoxide
    • C01B3/16—Production of hydrogen; Production of gaseous mixtures containing hydrogen by reaction of inorganic compounds containing electro-positively bound hydrogen with inorganic reducing agents by reaction of water vapour with carbon monoxide using catalysts
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen; Reversible storage of hydrogen
    • C01B3/50—Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification
    • C01B3/56—Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids
    • C01B3/58—Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids including a catalytic reaction
    • C01B3/583—Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids including a catalytic reaction the reaction being the selective oxidation of carbon monoxide
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen; Reversible storage of hydrogen
    • C01B3/50—Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification
    • C01B3/56—Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids
    • C01B3/58—Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids including a catalytic reaction
    • C01B3/586—Separation of hydrogen or hydrogen-containing gases from gaseous mixtures, e.g. purification by contacting with solids; Regeneration of used solids including a catalytic reaction the reaction being a methanation reaction
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C1/00—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon
    • C07C1/02—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon from oxides of a carbon
    • C07C1/04—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon from oxides of a carbon from carbon monoxide with hydrogen
    • C07C1/0425—Catalysts; their physical properties
    • C07C1/043—Catalysts; their physical properties characterised by the composition
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/06—Combination of fuel cells with means for production of reactants or for treatment of residues
    • H01M8/0662—Treatment of gaseous reactants or gaseous residues, e.g. cleaning
    • H01M8/0668—Removal of carbon monoxide or carbon dioxide
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
    • B01J2229/30—After treatment, characterised by the means used
    • B01J2229/42—Addition of matrix or binder particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
    • B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
    • B01J23/46—Ruthenium, rhodium, osmium or iridium
    • B01J23/462—Ruthenium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/63—Pore volume
    • B01J35/635—0.5-1.0 ml/g
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0435—Catalytic purification
    • C01B2203/044—Selective oxidation of carbon monoxide
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0435—Catalytic purification
    • C01B2203/0445—Selective methanation
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
    • C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
    • C01B2203/0465—Composition of the impurity
    • C01B2203/047—Composition of the impurity the impurity being carbon monoxide
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

  • the present invention is for a catalyst for the conversion of carbon monoxide. More specifically, this invention relates to catalyst comprising a support having a predetermined pore size and a metal capable of forming a metal carbonyl species.
  • the catalyst of the present invention comprises a mordenite, beta, or faujasite support and ruthenium metal.
  • a fuel cell such as a Polymer Electrolyte Membrane Fuel Cell (PEMFC) stack
  • chemical energy of a fuel is converted into electrical energy.
  • the fuel used is a hydrogen rich gas supplied to the fuel cell by a fuel processor.
  • the gas from the fuel processor may further comprise unconverted hydrocarbon, water, carbon dioxide and carbon monoxide.
  • the carbon monoxide in paiticular, is detrimental to the PEMFC stack because the carbon monoxide can poison the noble metal electrodes utilized by the fuel cells, thereby reducing the electrical output.
  • the CO concentration for a fuel cell feed should be at a level below about 100 ppm, and more preferably to a level of less than about 50 ppm.
  • the CO concentrations may be in excess of about 1 wt%, thus requiring further reduction of CO concentration.
  • Some typical methods for reducing the CO concentration include selective catalytic oxidation of CO, pressure swing adsorption, hydrogen separation by membrane, and selective methanation of CO.
  • Eq. 1 is favored over Eq. 2.
  • One option for achieving this is to have a highly specific catalyst for the oxidation of carbon monoxide and to limit the oxygen concentration so that the oxygen is consumed primarily for the production of carbon dioxide. Theoretically, this is achievable, but in practice there are wide swings in the CO concentrations produced by the fuel processor and it can be difficult to adjust the oxygen input to track the CO concentration. Because the CO is more detrimental to the fuel cell than water, it is typical for excess oxygen to be fed into the reactor thereby essentially ensuring that the CO will be converted to C0 2 . The disadvantage is that significant quantities of H 2 are converted to water by operating in this manner.
  • Pressure swing adsorption is an industrially proven technology, but it requires relatively high pressure operation. Thus, while this process may be effective for use in larger fuel cells, it is not practical at this time for smaller fuel cells.
  • Hydrogen separation by membrane is effective for separating hydrogen from carbon monoxide. But the process requires a substantial pressure drop to effect the separation, and the cost and durability of the membranes still must be proven.
  • Selective methanation is a process whereby carbon monoxide is reacted with hydrogen in the presence of a catalyst to produce methane and water and methanation of carbon dioxide is minimized.
  • total carbon oxide methanation is known to reduce carbon monoxide and carbon dioxide concentrations to levels as low as about 5 ppmv to 10 ppmv, and the industrial catalysts are not selective.
  • the selective methanation reaction is accompanied by a reverse water-gas-shift reaction (Eq. 4), which also is generally facilitated by a catalyst.
  • Eq. 4 reverse water-gas-shift reaction
  • the C0 2 may be methanated as shown in Eq. 5.
  • the CO concentration should be less than about 100 ppm, and preferably equal to or less than about 50 ppm. Since the CO concentration from the selective methanation processes using the prior art catalysts are significantly higher than the desired maximum concentration for a PEMFC stack, these catalysts cannot be practically used in PEMFC power systems.
  • the catalyst of the present invention comprises a metal capable of forming a metal-carbonyl species on a support having a predetermined pore size. More specifically, the catalyst comprises a metal selected from the group consisting of ruthenium, rhodium, nickel, iron, cobalt, rhenium, palladium, lead, tin and other metals that form a metal-carbonyl species on a support having a regular lattice structure and a predetermined pore diameter of sufficient dimensions to accommodate the carbonylated metal species, h an embodiment, the metal is ruthenium and the support is selected from mordenite, beta-zeolite or faujasite and has a pore diameter of greater than about 6.3 A, and a pore volume in the range of from about 0.3cm 3 /g to about 1.0cm 3 /g.
  • An inert binder such as alumina, ⁇ -Al 2 03, Si0 2 , Zr ⁇ 2, TiO 2 or pseudo-boehmite, may optionally be added to the catalyst.
  • the catalyst efficiently facilitates the selective hydrogenation of carbon monoxide using H 2 that is present in the reformate and reduces the concentration of the CO to levels equal to or less than about 50 ppm.
  • the present invention further includes a process for CO "polishing", whereby the concenfration of CO in a mixture of gases containing hydrogen, hydrocarbons, carbon dioxide, carbon monoxide and water is removed or substantially reduced.
  • this invention is directed to a method of selective methanation whereby carbon monoxide is reduced to a concentration level such that the residual hydrogen is suitable for use as a fuel in a fuel cell and the overall efficiency of the PEMFC power system is improved.
  • the catalyst of the present invention has demonstrated benefits in facilitating the carbon oxide methanation reactions in small fuel cells.
  • the catalyst comprises a metal capable of fonning a metal-carbonyl species on a support having a predetermined pore size of sufficient dimensions to allow the pore to accommodate a fully carbonylated metal complex.
  • some typical supports for catalysts are crystalline alumino-silicate materials.
  • the metals known in the art to form stable metal- carbonyl complexes are ruthenium, rhodium, nickel, iron, cobalt, rhenium, palladium, lead and tin, as an exemplary group.
  • an inert binder such as alumina, ⁇ -Al 2 0 3 , Si0 2 , Zr0 2 . Ti0 2 or pseudo-boehmite, may optionally be added to the catalyst.
  • the support of the catalyst of the present invention comprises a crystalline alumino-silicate having a predetermined pore size.
  • the crystalline alumino-silicate can be a molecular sieve, beta- zeolite, mordenite, faujasite or any other alumino-silicate with a regular lattice structure.
  • Other supports that also have regular lattice structures and essentially consistent pore sizes that may be used in place of the alumino-silicate for the catalyst of the present invention include alumina, titania, ceria, zirconia and combinations thereof.
  • the pore must be of sufficient dimensions to accommodate a fully carbonylated metal complex, and thus, the pore size requirement will vary depending on the metal species selected for the catalyst. However, it has generally been observed that if the pore size is smaller than or is significantly larger than the dimensions of the fully carbonylated metal species, the resulting catalyst does not show the desired selectivity for carbon monoxide methanation.
  • the metal of the catalyst of the present invention must be capable of farming a metal-carbonyl species.
  • metals may form metal-carbonyl complexes wherein each ligand is a carbonyl unit, such as Fe(CO) 5 , or metals may form metal-carbonyl complexes wherein at least one ligand is not a carbonyl, such as CpFe(CO) 3 .
  • the metal it is not necessary that the metal be capable of forming a fully-carbonylated complexes, e.g. wherein each ligand is a carbonyl group.
  • a "fully- carbonylated" complex - for the purpose of calculating the volume needed within the support pore - is defined herein as the metal complex with the maximum number of carbon monoxide ligands that the metal prefers to accommodate in its lowest energy state.
  • the metal is preferably selected from the group consisting of ruthenium, rhodium, platinum, palladium, rhenium, nickel, iron, cobalt, lead, tin, silver, iridium, gold, copper, manganese, zinc, zirconium, molybdenum, other metals that form a metal-carbonyl species and combinations thereof.
  • the metal may be a base metal or it may be a metal oxide complex.
  • the metal may be added to the support by any means known in the art for intercalating the metal into the support pores, such as, without limitation, impregnation, incipient wetness method, immersion and spraying.
  • the embodiments presented herein add the metal through impregnation for exemplary purposes only.
  • the metal source be free of typically recognized poisons, such as sulfur, chlorine, sodium, bromine, iodine or combinations thereof.
  • Acceptable catalyst can be prepared using metal sources that include such poisons, but care must be taken to wash the poisons from the catalyst during production of the catalyst.
  • the support is a crystalline alumino-silicate selected from mordenite, beta-zeolite or faujasite.
  • the support has a pore diameter of greater than about 6.3 A, and a pore volume in the range of from about 0.3cm 3 /g to about 1.0cm 3 /g, and preferably in the range of 0.5cm 3 /g to about 0.8cm 3 /g.
  • Ruthenium is impregnated on the support so as to deliver a concentration of from about 0.5 wt% Ru to about 4.5 wt% Ru, based on the total weight of the catalyst including the ruthenium.
  • the catalyst further comprises the binder ⁇ -Al 2 0 3 at a loading of about 20 wt%, including the weight of the binder.
  • the catalyst may be used in an exemplary process for removing or substantially reducing the quantity of carbon monoxide in a mixture of gases containing hydrogen, carbon dioxide, carbon monoxide, and water.
  • the process involves passing a mixture of gases over the catalyst in a reaction zone having a temperature below the temperature at which the shift reaction occurs and above the temperature at which the selective methanation of carbon monoxide occurs.
  • catalysts of the present invention are intended for use as selective methanation catalysts for the conversion of carbon monoxide for fuel cell applications, it is anticipated that these catalysts could be used in other applications requiring highly selective carbon oxide methanation catalysts.

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Abstract

A catalyst for the conversion of carbon monoxide comprising a support having a predetermined pore size and a metal capable of forming a metal carbonyl species is described. In one embodiment, the catalyst of the present invention comprises a mordenite, beta, or faujasite support and ruthenium metal.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to U. S . Provisional Application Serial Number 60/516,230 filed on October 31, 2003 and incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is for a catalyst for the conversion of carbon monoxide. More specifically, this invention relates to catalyst comprising a support having a predetermined pore size and a metal capable of forming a metal carbonyl species. In one embodiment, the catalyst of the present invention comprises a mordenite, beta, or faujasite support and ruthenium metal.
2. Description of the Related Art
In a fuel cell, such as a Polymer Electrolyte Membrane Fuel Cell (PEMFC) stack, chemical energy of a fuel is converted into electrical energy. Typically, the fuel used is a hydrogen rich gas supplied to the fuel cell by a fuel processor. However, the gas from the fuel processor may further comprise unconverted hydrocarbon, water, carbon dioxide and carbon monoxide. The carbon monoxide, in paiticular, is detrimental to the PEMFC stack because the carbon monoxide can poison the noble metal electrodes utilized by the fuel cells, thereby reducing the electrical output.
Preferably, the CO concentration for a fuel cell feed should be at a level below about 100 ppm, and more preferably to a level of less than about 50 ppm. However, as received from the fuel processor, the CO concentrations may be in excess of about 1 wt%, thus requiring further reduction of CO concentration. Some typical methods for reducing the CO concentration include selective catalytic oxidation of CO, pressure swing adsorption, hydrogen separation by membrane, and selective methanation of CO.
Selective catalytic oxidation of CO (Eq. 1 ) is a well-known process for reducing the CO concentration for fuel cells. But, oxidation of hydrogen (Eq.2) is a competitive reaction. y2 02 + CO → C02 Eq. 1
Figure imgf000003_0001
Thus, in order to maximize the concentration of hydrogen gas and minimize the concentration of carbon monoxide, it is necessary to have reaction conditions wherein Eq. 1 is favored over Eq. 2. One option for achieving this is to have a highly specific catalyst for the oxidation of carbon monoxide and to limit the oxygen concentration so that the oxygen is consumed primarily for the production of carbon dioxide. Theoretically, this is achievable, but in practice there are wide swings in the CO concentrations produced by the fuel processor and it can be difficult to adjust the oxygen input to track the CO concentration. Because the CO is more detrimental to the fuel cell than water, it is typical for excess oxygen to be fed into the reactor thereby essentially ensuring that the CO will be converted to C02. The disadvantage is that significant quantities of H2 are converted to water by operating in this manner.
Pressure swing adsorption is an industrially proven technology, but it requires relatively high pressure operation. Thus, while this process may be effective for use in larger fuel cells, it is not practical at this time for smaller fuel cells.
Hydrogen separation by membrane is effective for separating hydrogen from carbon monoxide. But the process requires a substantial pressure drop to effect the separation, and the cost and durability of the membranes still must be proven.
Selective methanation (Eq. 3) is a process whereby carbon monoxide is reacted with hydrogen in the presence of a catalyst to produce methane and water and methanation of carbon dioxide is minimized. Commonly used in ammonia plants, total carbon oxide methanation is known to reduce carbon monoxide and carbon dioxide concentrations to levels as low as about 5 ppmv to 10 ppmv, and the industrial catalysts are not selective. However, in most fuel cell applications, the selective methanation reaction is accompanied by a reverse water-gas-shift reaction (Eq. 4), which also is generally facilitated by a catalyst. Thus, while the CO concentration is being reduced through methanation, additional carbon monoxide is formed from the carbon dioxide present to maintain the equilibrium of the water-gas-shift reaction. CO + 3H2 → CH4 + H20 Eq. 3
C02 + H2 «→ CO + H20 Eq. 4
Under the proper reaction conditions and with a non-selective methanation catalyst, the C02 may be methanated as shown in Eq. 5.
C02 + 4H2 → CH, + 2H20 Eq. 5
But, this is generally an undesirable reaction because it further consumes H2 and the C02 methanation is normally accompanied by a temperature rise in the reactor that can lead to "run-away" conditions. Considering that the carbon dioxide concentration is greater than 10 times that of carbon monoxide, achieving selectivity is not thermodynamically favorable. Thus, it would be advantageous to have a catalyst that is highly selective for CO methanation, essentially suppresses C02 methanation and does not facilitate the conversion of C02 to CO through the water-gas-shift reaction.
In the prior art methanation processes, precious metals supported on noil-zeolitic materials, such as A1203, Si02, and Ti02 , have been used as catalysts in the selective methanation of CO (see, for example, U.S. Pat. No. 3,615,164 and U.S. Pat. Pub. No. 2003/0086866). For example, in Patent Number WO 01/64337, ruthenium (Ru) on a carrier base support of AI2O3, Ti02, Si02, Zr02, or Al203-Ti02 with egg-shell structure is taught to reduce the CO to concentrations of about 800 ppm with 70-80% selectivity under an atmosphere of CO at 0.6%, C02 at 15%, H2 at 64.4%, H20 at 20% and GHSV = 10,000 H"1. However, for an efficient PEMFC power system, the CO concentration should be less than about 100 ppm, and preferably equal to or less than about 50 ppm. Since the CO concentration from the selective methanation processes using the prior art catalysts are significantly higher than the desired maximum concentration for a PEMFC stack, these catalysts cannot be practically used in PEMFC power systems.
Thus, it would be advantageous to have a catalyst that is highly selective for CO methanation, essentially suppresses C0 methanation and does not facilitate the conversion of C02 to CO through the water- gas-shift reaction. SUMMARY OF THE INVENTION
The catalyst of the present invention comprises a metal capable of forming a metal-carbonyl species on a support having a predetermined pore size. More specifically, the catalyst comprises a metal selected from the group consisting of ruthenium, rhodium, nickel, iron, cobalt, rhenium, palladium, lead, tin and other metals that form a metal-carbonyl species on a support having a regular lattice structure and a predetermined pore diameter of sufficient dimensions to accommodate the carbonylated metal species, h an embodiment, the metal is ruthenium and the support is selected from mordenite, beta-zeolite or faujasite and has a pore diameter of greater than about 6.3 A, and a pore volume in the range of from about 0.3cm3/g to about 1.0cm3/g. An inert binder, such as alumina, γ-Al203, Si02, Zrθ2, TiO2 or pseudo-boehmite, may optionally be added to the catalyst. The catalyst efficiently facilitates the selective hydrogenation of carbon monoxide using H2 that is present in the reformate and reduces the concentration of the CO to levels equal to or less than about 50 ppm.
The present invention further includes a process for CO "polishing", whereby the concenfration of CO in a mixture of gases containing hydrogen, hydrocarbons, carbon dioxide, carbon monoxide and water is removed or substantially reduced. Particularly, this invention is directed to a method of selective methanation whereby carbon monoxide is reduced to a concentration level such that the residual hydrogen is suitable for use as a fuel in a fuel cell and the overall efficiency of the PEMFC power system is improved.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The catalyst of the present invention has demonstrated benefits in facilitating the carbon oxide methanation reactions in small fuel cells. In general terms, the catalyst comprises a metal capable of fonning a metal-carbonyl species on a support having a predetermined pore size of sufficient dimensions to allow the pore to accommodate a fully carbonylated metal complex. As is known in the art, some typical supports for catalysts are crystalline alumino-silicate materials. Among the metals known in the art to form stable metal- carbonyl complexes are ruthenium, rhodium, nickel, iron, cobalt, rhenium, palladium, lead and tin, as an exemplary group. Optionally, an inert binder, such as alumina, γ-Al203, Si02, Zr02. Ti02 or pseudo-boehmite, may optionally be added to the catalyst.
The present invention will be described herein through, without limitation, exemplary embodiments, figures and examples. Any embodiments, figures, examples and related data presented herein are merely to exemplify the principles of the invention, and are not intended to limit the scope of the invention.
The support of the catalyst of the present invention comprises a crystalline alumino-silicate having a predetermined pore size. More specifically, the crystalline alumino-silicate can be a molecular sieve, beta- zeolite, mordenite, faujasite or any other alumino-silicate with a regular lattice structure. Other supports that also have regular lattice structures and essentially consistent pore sizes that may be used in place of the alumino-silicate for the catalyst of the present invention include alumina, titania, ceria, zirconia and combinations thereof. Because it is believed that the methanation reaction occurs within the support pore, the pore must be of sufficient dimensions to accommodate a fully carbonylated metal complex, and thus, the pore size requirement will vary depending on the metal species selected for the catalyst. However, it has generally been observed that if the pore size is smaller than or is significantly larger than the dimensions of the fully carbonylated metal species, the resulting catalyst does not show the desired selectivity for carbon monoxide methanation.
The metal of the catalyst of the present invention must be capable of farming a metal-carbonyl species. As is known in the art, metals may form metal-carbonyl complexes wherein each ligand is a carbonyl unit, such as Fe(CO)5, or metals may form metal-carbonyl complexes wherein at least one ligand is not a carbonyl, such as CpFe(CO)3. For the purpose of the development, it is not necessary that the metal be capable of forming a fully-carbonylated complexes, e.g. wherein each ligand is a carbonyl group. Rather, a "fully- carbonylated" complex - for the purpose of calculating the volume needed within the support pore - is defined herein as the metal complex with the maximum number of carbon monoxide ligands that the metal prefers to accommodate in its lowest energy state. The metal is preferably selected from the group consisting of ruthenium, rhodium, platinum, palladium, rhenium, nickel, iron, cobalt, lead, tin, silver, iridium, gold, copper, manganese, zinc, zirconium, molybdenum, other metals that form a metal-carbonyl species and combinations thereof. As delivered to the catalyst, the metal may be a base metal or it may be a metal oxide complex.
The metal may be added to the support by any means known in the art for intercalating the metal into the support pores, such as, without limitation, impregnation, incipient wetness method, immersion and spraying. The embodiments presented herein add the metal through impregnation for exemplary purposes only. Although not a requirement to practice the invention, it is recommended that the metal source be free of typically recognized poisons, such as sulfur, chlorine, sodium, bromine, iodine or combinations thereof. Acceptable catalyst can be prepared using metal sources that include such poisons, but care must be taken to wash the poisons from the catalyst during production of the catalyst.
In an embodiment of the present invention, the support is a crystalline alumino-silicate selected from mordenite, beta-zeolite or faujasite. The support has a pore diameter of greater than about 6.3 A, and a pore volume in the range of from about 0.3cm3/g to about 1.0cm3/g, and preferably in the range of 0.5cm3/g to about 0.8cm3/g. Ruthenium is impregnated on the support so as to deliver a concentration of from about 0.5 wt% Ru to about 4.5 wt% Ru, based on the total weight of the catalyst including the ruthenium. Some recommended sources of ruthenium include, without limitation, Ru(NO)(N03)x(OH)y, Ru(N02)2(N03)2, Ru(N03)3, RuCl3, Ru(CH3C003), (NH4)2RuCl6, [Ru(NH3)6]Cl3, Ru(NO)Cl3, and Ru3(CO)12. Optionally, the catalyst further comprises the binder γ-Al203 at a loading of about 20 wt%, including the weight of the binder. The catalyst may be used in an exemplary process for removing or substantially reducing the quantity of carbon monoxide in a mixture of gases containing hydrogen, carbon dioxide, carbon monoxide, and water. The process involves passing a mixture of gases over the catalyst in a reaction zone having a temperature below the temperature at which the shift reaction occurs and above the temperature at which the selective methanation of carbon monoxide occurs.
It is understood that variations may be made which would fall within the scope of this development. For example, although the catalysts of the present invention are intended for use as selective methanation catalysts for the conversion of carbon monoxide for fuel cell applications, it is anticipated that these catalysts could be used in other applications requiring highly selective carbon oxide methanation catalysts.

Claims

What is claimed is:
1. A catalyst for carbon oxide methanation reactions for fuel cells comprising a metal capable of forming a metal-carbonyl species on a support having a predetermined pore size of sufficient dimensions to allow the pore to accommodate a fully carbonylated metal complex.
2. The catalyst of Claim 1 wherein the support is a crystalline alumino-silicate.
3. The catalyst of Claim 1 wherein the support is selected from the group consisting of a molecular sieve, beta-zeolite, mordenite, faujasite, any other alumino-silicate with a regular lattice structure, alumina, titania, ceria, zirconia and combinations thereof.
4. The catalyst of Claim 3 wherein the support is selected from the group consisting of a beta-zeolite, mordenite, and faujasite.
5. The catalyst of Claim 1 wherein the metal is selected from the group consisting of ruthenium, rhodium, platinum, palladium, rhenium, nickel, iron, cobalt, lead, tin, silver, iridium, gold, copper, manganese, zinc, zirconium, molybdenum, other metals that form a metal-carbonyl species and combinations thereof.
6. The catalyst of Claim 5 wherein the metal is selected from the group consisting of ruthenium, rhodium and nickel.
7. The catalyst of Claim 6 wherein the metal is ruthenium.
8. The catalyst of Claim 1 further comprising an inert binder.
9. The catalyst of Claim 8 wherein the binder is selected from the group consisting of alumina, γ-Al203, Si02, Zr02, Ti02 or pseudo-boehmite.
10. The catalyst of Claim 1 wherein the metal is added to the support through impregnation, incipient wetness method, immersion and spraying.
11. The catalyst of Claim 7 wherein the ruthenium is added to the support through impregnation.
12. The catalyst of Claim 4 wherein the support has a pore volume in the range of from about 0.3cm3/g to about 1.0cm3/g.
13. The catalyst of Claim 12 wherein the metal is ruthenium impregnated on the support so as to deliver a concentration of from about 0.5 wt% Ru to about 4.5 wt% Ru, based on the total weight of the catalyst including the ruthenium.
14. A catalyst for carbon oxide methanation reactions for fuel cells comprising a metal capable of fonning a metal-carbonyl species on a support having a pore volume in the range of from about 0.3cm3/g to about 1.0cm3/g.
15. The catalyst of Claim 14 wherein the support is selected from the group consisting of a crystalline alumino-silicate, a molecular sieve, beta-zeolite, mordenite, faujasite, any other alumino-silicate with a regular lattice structure, alumina, titania, ceria, zirconia and combinations thereof.
16. The catalyst of Claim 14 wherein the metal is selected from the group consisting of ruthenium, rhodium, platinum, palladium, rhenium, nickel, iron, cobalt, lead, tin, silver, iridium, gold, copper, manganese, zinc, zirconium, molybdenum, other metals that form a metal-carbonyl species and combinations thereof.
17. The catalyst of Claim 14 further comprising an inert binder.
18. The catalyst of Claim 17 wherein the binder is selected from the group consisting of alumina, γ-Al203, Si02, Zrθ2, Ti02 or pseudo-boehmite.
19. The catalyst of Claim 14 wherein the metal is ruthenium impregnated on the support so as to deliver a concentration of from about 0.5 wt% Ru to about 4.5 wt% Ru, based on the total weight of the catalyst including the ruthenium.
20. A catalyst for carbon oxide methanation reactions for fuel cells comprising a metal selected from the group consisting of ruthenium, rhodium, platinum, palladium, rhenium, nickel, iron, cobalt, lead, tin, silver, iridium, gold, copper, manganese, zinc, zirconium, molybdenum, other metals that form a metal-carbonyl species and combinations thereof on a support having a pore volume in the range of from about 0.3cm3/g to about 1.0cm3/g, wherein the support is selected from the group consisting of a crystalline alumino-silicate, a molecular sieve, beta-zeolite, mordenite, faujasite, any other alumino-silicate with a regular lattice structure, alumina, titania, ceria, zirconia and combinations thereof.
21. The catalyst of Claim 20 further comprising a binder selected from the group consisting of alumina, γ- A1203, Si02, Zr02, Ti02 or pseudo-boehmite.
22. The catalyst of Claim 20 wherein the metal is ruthenium impregnated on the support so as to deliver a concentration of from about 0.5 wt% Ru to about 4.5 wt% Ru, based on the total weight of the catalyst including the ruthenium.
23. A catalyst for carbon oxide methanation reactions for fuel cells comprising ruthenium impregnated on the support so as to deliver a concentration of from about 0.5 wt% Ru to about 4.5 wt% Ru, based on the total weight of the catalyst including the ruthenium, wherein the support is selected from the group consisting of a beta-zeolite, mordenite and faujasite.
24. The catalyst of Claim 23 wherein the support has a pore diameter of greater than about 6.3 A and a pore volume in the range of from about 0.3cm3/g to about l.OcmVg.
25. The catalyst of Claim 23 wherein the catalyst further comprises the binder γ-Al203 at a loading of about 20 wt%, including the weight of the binder.
26. A method for carbon oxide methanation reactions for fuel cells using a catalyst comprising a metal capable of forming a metal-carbonyl species on a support having a predetermined pore size of sufficient dimensions to allow the pore to accommodate a fully carbonylated metal complex, the method comprising passing a mixture of gases over the catalyst in a reaction zone having a temperature below the temperature at which the shift reaction occurs and above the temperature at which the selective methanation of carbon monoxide occurs.
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