U.S. patent application number 10/035575 was filed with the patent office on 2002-09-19 for platinum group metal promoted copper oxidation catalysts and methods for carbon monoxide remediation.
Invention is credited to Farrauto, Robert J., Ruettinger, Wolfgang F., Shore, Lawrence.
Application Number | 20020131915 10/035575 |
Document ID | / |
Family ID | 27100048 |
Filed Date | 2002-09-19 |
United States Patent
Application |
20020131915 |
Kind Code |
A1 |
Shore, Lawrence ; et
al. |
September 19, 2002 |
Platinum group metal promoted copper oxidation catalysts and
methods for carbon monoxide remediation
Abstract
The invention provides copper-based preferential oxidation
catalysts containing low concentrations of platinum group metals.
In some embodiments, the catalysts of the invention have an oxide
support on which is dispersed copper or an oxide thereof, a
platinum group metal and a reducible metal oxide. In other
embodiments, the catalysts have a cerium oxide support on which is
dispersed copper or an oxide thereof and a platinum group metal.
The catalysts serve as effective preferential oxidation catalyst
that selectively oxidize carbon monoxide with minimal consumption
of hydrogen. In some embodiments the catalysts of the invention are
able to achieve levels of carbon monoxide below 10 ppm in output
gas streams containing hydrogen operating with wide temperature
ranges. The invention also provides apparatus, such as fuel
processors, that supply hydrogen to a fuel cell, that incorporate
the preferential oxidation catalysts.
Inventors: |
Shore, Lawrence; (Edison,
NJ) ; Ruettinger, Wolfgang F.; (East Windsor, NJ)
; Farrauto, Robert J.; (Princeton, NJ) |
Correspondence
Address: |
Stephen I. Miller, Chief Patent Counsel
Engelhard Corporation
101 Wood Avenue
Iselin
NJ
08830-0770
US
|
Family ID: |
27100048 |
Appl. No.: |
10/035575 |
Filed: |
November 9, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10035575 |
Nov 9, 2001 |
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09771812 |
Jan 29, 2001 |
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09771812 |
Jan 29, 2001 |
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09669044 |
Sep 25, 2000 |
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Current U.S.
Class: |
422/177 ;
422/211; 502/304; 502/318; 502/324; 502/326; 502/331 |
Current CPC
Class: |
Y02P 20/52 20151101;
C01B 2203/0205 20130101; B01J 23/868 20130101; C01B 2203/047
20130101; B01J 37/0248 20130101; H01M 8/0662 20130101; C01B 3/16
20130101; C01B 3/583 20130101; C01B 2203/0283 20130101; B01J 23/894
20130101; H01M 8/0612 20130101; Y02E 60/50 20130101; B01J 23/56
20130101; B01J 23/63 20130101; C01B 2203/146 20130101; C01B
2203/066 20130101; C01B 2203/044 20130101; B01J 23/83 20130101;
B01J 37/0205 20130101; B01J 23/76 20130101 |
Class at
Publication: |
422/177 ;
502/331; 502/304; 502/324; 502/326; 502/318; 422/211 |
International
Class: |
B01D 053/62; B01J
023/72 |
Claims
What is claimed:
1. A preferential oxidation catalyst for the oxidation of carbon
monoxide to carbon dioxide in the presence of excess hydrogen,
comprising: at least 50 wt. % of an oxide support selected from the
group consisting of activated alumina, zirconia, titania, silica,
zeolites and combinations thereof; 5 wt. % or more copper or an
oxide thereof dispersed on the oxide support; 0.01 to 0.5 wt. % of
a platinum group metal selected from the group consisting of
platinum, palladium, rhodium, osmium, iridium, ruthenium and
combinations thereof dispersed on the oxide support; and at least
10 wt. % of a reducible metal oxide selected from the group
consisting of oxides of chromium, vanadium, molybdenum, cerium,
praseodymium, neodymium, titanium, nickel, manganese, cobalt, and
combinations thereof dispersed on the oxide support.
2. The preferential oxidation catalyst of claim 1, wherein the
platinum group metal comprises platinum.
3. The preferential oxidation catalyst of claim 1, wherein the
oxide support comprises activated alumina.
4. The preferential oxidation catalyst of claim 1, wherein the
reducible metal oxide comprises cerium oxide.
5. A preferential oxidation catalyst for the oxidation of carbon
monoxide to carbon dioxide in the presence of excess hydrogen,
comprising: at least 50 wt. % of an alumina support; 5 wt. % or
more copper or an oxide thereof dispersed on the alumina support;
0.01 to 0.5 wt. % of a platinum group metal selected from the group
consisting of platinum, palladium, rhodium, osmium, iridium,
ruthenium and combinations thereof dispersed on the alumina
support; and at least 10 wt. % of cerium oxide dispersed on the
alumina support.
6. The preferential oxidation catalyst of claim 5, wherein the
platinum group metal comprises platinum.
7. The preferential oxidation catalyst of claim 6, wherein there
is: at least 65 wt. % of the alumina support; 5 to 14 wt. % of
copper or an oxide thereof dispersed on the alumina support; 0.01
to 0.5 wt. % of platinum in the alumina support; and 10 to 25 wt. %
of cerium oxide dispersed on the alumina support.
8. The preferential oxidation catalyst of claim 5, wherein the
alumina support is in the form of support particles having a mesh
size of 12 or greater, and a BET surface area of 10 m.sup.2/g or
greater.
9. The preferential oxidation catalyst of claim 5, wherein the
preferential oxidation catalyst is in the form of a washcoat
composition deposited on a monolith substrate.
10. A preferential oxidation catalyst for the oxidation of carbon
monoxide to carbon dioxide in the presence of excess hydrogen,
comprising: a cerium oxide support; copper or an oxide thereof
dispersed on the cerium oxide support; and 0.2 wt. % or more of a
platinum group metal selected from the group consisting of
platinum, palladium, rhodium, osmium, iridium, ruthenium and
combinations thereof dispersed on the cerium oxide support.
11. The preferential oxidation catalyst of claim 10, wherein the
platinum group metal comprises platinum.
12. The preferential oxidation catalyst of claim 11, wherein there
is: 5 to 14 wt. % of copper or an oxide thereof dispersed on the
cerium oxide support; and 0.2 to 5 wt. % platinum dispersed on the
cerium oxide support.
13. The preferential oxidation catalyst of claim 10, wherein the
preferential oxidation catalyst is in the form of a washcoat
composition deposited on a monolith substrate.
14. The preferential oxidation catalyst of claim 13, further
comprising a binder.
15. An apparatus for supplying hydrogen to a PEM fuel cell, wherein
the apparatus has a hydrocarbon reformer reactor, a water-gas shift
reactor, a preferential oxidation reactor having a preferential
oxidation catalyst, wherein the preferential oxidation catalyst
comprises: at least 50 wt. % of an alumina support; 5 wt. % or more
copper or an oxide thereof dispersed on the alumina support; 0.01
to 0.5 wt. % of a platinum group metal selected from the group
consisting of platinum, palladium, rhodium, osmium, iridium,
ruthenium and combinations thereof dispersed on the alumina
support; and at least 10 wt. % cerium oxide dispersed on the
alumina support; wherein the hydrocarbon reformer reactor is
upstream and in train with the water-gas shift reactor, and the
preferential oxidation catalyst is downstream and in train with the
water-gas shift reactor.
16. An apparatus for supplying hydrogen to a PEM fuel cell, wherein
the apparatus has a hydrocarbon reformer reactor, a water-gas shift
reactor, a preferential oxidation reactor having a selective
oxidation catalyst, wherein the preferential oxidation catalyst
comprises: a cerium oxide support; copper or an oxide thereof
dispersed on the cerium oxide support; and 0.2 wt. % or more of a
platinum group metal selected from the group consisting of
platinum, palladium, rhodium, osmium, iridium, ruthenium and
combinations thereof dispersed on the cerium oxide support; wherein
the hydrocarbon reformer reactor is upstream and in train with the
water-gas shift reactor, and the preferential oxidation catalyst is
downstream and in train with the water-gas shift reactor.
17. An article for selectively oxidizing carbon monoxide in a gas
stream comprising carbon monoxide and hydrogen, the article
comprising: an upstream preferential oxidation catalyst; and a
downstream preferential oxidation catalyst in fluid connection with
the first preferential oxidation catalyst, wherein the downstream
preferential oxidation catalyst comprises: at least 50 wt. % of an
alumina support; 5 wt. % or more copper or an oxide thereof
dispersed on the alumina support; 0.01 to 0.5 wt. % of a platinum
group metal selected from the group consisting of platinum,
palladium, rhodium, osmium, iridium, ruthenium and combinations
thereof dispersed on the alumina support; and at least 10 wt. %
cerium oxide dispersed on the alumina support.
18. The article of claim 17, wherein the platinum group metal of
the downstream preferential oxidation catalyst comprises
platinum.
19. An article for selectively oxidizing carbon monoxide in a gas
stream comprising carbon monoxide and hydrogen, the article
comprising: an upstream preferential oxidation catalyst; and a
downstream preferential oxidation catalyst in fluid connection with
the first preferential oxidation catalyst, wherein the downstream
preferential oxidation catalyst comprises: a cerium oxide support;
copper or an oxide thereof dispersed on the cerium oxide support;
and 0.2 wt. % or more of a platinum group metal selected from the
group consisting of platinum, palladium, rhodium, osmium, iridium,
ruthenium and combinations thereof dispersed on the cerium oxide
support.
20. The article of claim 19, wherein the platinum group metal of
the downstream preferential oxidation catalyst comprises platinum.
Description
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 09/771,812, filed Jan. 29, 2001, which is a
continuation-in-part of U.S. patent application Ser. No. 09/669,044
filed Sep. 25, 2000, now abandoned. The disclosures of both of
these applications are incorporated herein by reference as if fully
set forth herein.
[0002] The present invention relates to preferential oxidation
catalysts and methods for the selective oxidation of carbon
monoxide in gas streams containing high concentrations of hydrogen.
More particularly, the invention relates to copper catalysts that
contain low levels of platinum group metals that stabilize the
catalyst composition against deactivation that typically occurs in
copper-based catalysts at lower temperatures e.g., below about
140.degree. C. The catalysts and methods of the invention are
useful, for example, for removing carbon monoxide in hydrogen feed
streams supplied to fuel cells, particularly to proton exchange
membrane (PEM) fuel cells.
[0003] Fuel cells directly convert chemical energy into electricity
thereby eliminating the mechanical process steps that limit
thermodynamic efficiency, and have been proposed as a power source
for many applications. The fuel cell can be two to three times as
efficient as the internal combustion engine with little, if any,
emission of primary pollutants such as carbon monoxide,
hydrocarbons and nitric oxides. Fuel cell-powered vehicles which
reform hydrocarbons to power the fuel cell generate less carbon
dioxide (green house gas) and have enhanced fuel efficiency.
[0004] Fuel cell processors (also known as fuel cell reformers)
supply a hydrogen-containing gas stream to the fuel cell. Fuel cell
processors include reactors that steam reform hydrocarbon
feedstocks (e.g., natural gas, LPG) and hydrocarbon derivatives
(e.g., alcohols) to produce a process stream enriched in hydrogen.
Other by-products from the steam reforming of hydrocarbon include
carbon monoxide and carbon dioxide. Fuel cell processors further
include shift reactors where the hydrogen content of the process
stream is further enriched by reaction of carbon monoxide in the
water-gas shift reaction:
CO+H.sub.2OCO.sub.2+H.sub.2
[0005] Fuel cells, including PEM fuel cells [also called solid
polymer electrolyte or (SPE) fuel cells], generate electrical power
in a chemical reaction between a reducing agent (hydrogen) and an
oxidizing agent (oxygen) which are fed to the fuel cells. A PEM
fuel cell includes an anode and a cathode separated by a membrane
which is usually an ion exchange resin membrane. The anode and
cathode electrodes are typically constructed from finely divided
carbon particles, catalytic particles supported on the carbon
particles and proton conductive resin intermingled with the
catalytic and carbon particles. In typical PEM fuel cell operation,
hydrogen gas is electrolytically oxidized to hydrogen ions at the
anode composed of platinum reaction catalysts deposited on a
conductive carbon electrode. The protons pass through the ion
exchange resin membrane, which can be a fluoropolymer of sulfonic
acid called a proton exchange membrane. H.sub.2O is produced when
protons then combine with oxygen that has been electrolytically
reduced at the cathode. The electrons flow through an external
circuit in this process to do work, creating an electrical
potential across the electrodes. Examples of membrane electrode
assemblies and fuel cells are described in U.S. Pat. No.
5,272,017.
[0006] The platinum electrodes at the anode are extremely sensitive
to carbon monoxide in the hydrogen feed stream supplied to the fuel
cell. Even levels below 100 ppm of carbon monoxide can cause
deterioration of the platinum and consequently, adversely affect
fuel cell performance. It is therefore desirable to reduce the
levels of carbon monoxide in the hydrogen feed stream supplied to
the fuel cell to as low a level as practical. Preferably, the level
of carbon monoxide in the hydrogen feed stream ultimately supplied
to the fuel cell is below 100 ppm, more preferably below 10
ppm.
[0007] Levels of carbon monoxide as low as these are difficult to
achieve by using the water-gas shift reactor alone, and so
additional carbon monoxide purifying measures are typically used.
One well-known method utilized to lower the levels of carbon
monoxide in hydrogen feed streams includes treatment with
"preferential oxidation catalysts" (also known as "Prox"
catalysts). These catalysts selectively oxidize residual carbon
monoxide in hydrogen gas streams according to the following
reaction:
CO+{fraction (1/2)}O.sub.2.fwdarw.CO.sub.2
[0008] wherein hydrogen may comprise greater than 60% by volume or
more of the gas stream composition. An undesirable side reaction in
this method is therefore the oxidation of hydrogen according to the
following reaction:
H.sub.2+1/2O.sub.2.fwdarw.H.sub.2O.
[0009] In order to consume as little hydrogen as possible, it is
preferable that the preferential oxidation process be as selective
as possible for the oxidation of carbon monoxide. Some of the
factors that influence the selectivity of the oxidation process
include the composition of the input gas stream used in the
process, the temperature of the reaction, the space velocity of the
input gas stream and the composition of the preferential oxidation
catalyst.
[0010] Some of the more effective preferential oxidation catalysts,
used in purifying hydrogen feed streams in fuel reformers, are
platinum-based catalysts, e.g., platinum on an alumina support.
While effective at catalyzing the selective oxidation at
temperatures above the dew point of the reforrnate gas stream,
achieving levels of carbon monoxide below 10 ppm in gas streams
containing high hydrogen content is difficult to accomplish. It is
believed that levels of carbon monoxide below 10 ppm cannot be
reached due to the reverse water-gas shift activity exhibited by
the platinum-based catalysts. At the low space velocities of the
input gas stream necessary to reach the equilibrium carbon monoxide
concentration, the long residence time and the high concentration
of hydrogen and carbon dioxide contribute begin to favor the
reverse water-gas shift and the detrimental formation of carbon
monoxide. An additional liability is the expense of including
catalytically effective amounts of costly platinum in the catalyst
composition.
[0011] An alternative preferential oxidation catalyst is a catalyst
containing ruthenium as a catalytic agent, e.g., ruthenium on an
alumina support. The ruthenium-based catalyst does not catalyze the
reverse water-gas shift reaction, and hydrogen feed streams with
levels of carbon monoxide below 10 ppm can be achieved. The
temperatures at which the selective oxidation processes using a
ruthenium-based catalyst are operated, however, are also favorable
for the methanation reaction that occurs with carbon monoxide as
shown below
CO+3H.sub.2.fwdarw.CH.sub.4+H.sub.2O
[0012] This undesired side reaction sacrifices three moles of
hydrogen for each mole of carbon monoxide converted to methane.
Methanation may also occur under these conditions with carbon
dioxide according to the equation shown below:
CO.sub.2+4H.sub.2.fwdarw.CH.sub.4+2H.sub.2O.
[0013] In this side reaction four moles of hydrogen are consumed
for each mole of carbon dioxide converted to methane. In addition,
ruthenium is a costly, precious metal that is in limited
supply.
[0014] Less costly preferential oxidation catalysts employ base
metals as preferential oxidation catalysts in fuel cell reformers.
For example, a copper/cerium oxide catalyst composition has been
described in WO 01/60738 to catalyze the selective oxidation of
carbon monoxide in hydrogen feed streams. The performance
characteristics of the catalyst are not described in the presence
of steam in this publication, however, a paper [Avgouropoulis et
al. Catalysis Letters 2001, 73, 33] described the effect of 10%
steam on the performance of these catalysts. To obtain a given
level of carbon monoxide conversion in the presence of steam, a
20-40.degree. C. increase in operating temperature was needed under
dry conditions. Exposure to high steam conditions are an intrinsic
part of fuel cell processor operation.
[0015] In addition, these copper-based catalyst typically operate
at higher temperatures however, which typically result in lower
selectivity. The selectivity of the reduction can be improved by
decreasing the reaction temperature, however, the catalyst is prone
to deactivation when the temperature drops below about 140.degree.
C. Such temperature drops are common in fuel cell applications
since power demands for fuel cells vary considerably depending on
the application. Preferential oxidation catalysts for incorporation
into fuel cell processors are therefore preferably designed to
withstand such temperature drops that are characteristic of
transient operation.
SUMMARY OF THE INVENTION
[0016] In one aspect, the invention relates to a preferential
oxidation catalyst for the oxidation of carbon monoxide to carbon
dioxide in the presence of excess hydrogen. The preferential
oxidation catalyst has at least 50 wt. % of an oxide support that
contains activated alumina, zirconia, titania, silica, zeolites and
combinations thereof. Preferred supports include activated alumina.
Dispersed on the oxide support is copper or an oxide thereof, a
platinum group metal and a reducible metal oxide.
[0017] Preferably there is at least 5 wt. % or more of copper in
the preferential oxidation catalyst.
[0018] The platinum group metal is selected from the group
consisting of platinum, palladium, rhodium, osmium, iridium,
ruthenium and combinations thereof, and is preferably in a
concentration range of 0.01 to 0.5 wt. % of the catalyst
composition. A preferred platinum group metal is platinum.
[0019] The reducible metal oxide is preferably selected from the
group consisting of oxides of chromium, vanadium, molybdenum,
cerium, praseodymium, neodymium, titanium, nickel, manganese,
cobalt, and combinations thereof. Preferred preferential oxidation
catalysts contain cerium oxide in the composition. The preferential
oxidation catalysts preferably contain at least 10 wt. % of the
reducible metal oxide.
[0020] In a particularly preferred embodiment of the invention, the
preferential oxidation catalyst has at least 65 wt. % of an alumina
support. Dispersed on the support are: 5 to 14 wt. % of copper or
an oxide thereof, 0.01 to 0.5 wt. % of platinum, and 10 to 25 wt. %
of cerium oxide.
[0021] In some embodiments the catalyst is in the form of support
particles having a mesh size of 12 or greater, and a BET surface
area of 10 m.sup.2/g or greater. The support particles preferably
are durable and possess high mechanical strength. In other
embodiments the preferential oxidation catalyst is in the form of a
washcoat composition deposited on a monolith substrate. The
catalyst can also take the form of extrudates or tablets.
[0022] In another aspect, the invention relates to a preferential
oxidation catalyst having a cerium oxide support on which is
dispersed copper or an oxide thereof, and 0.2 wt. % or more of a
platinum group metal. Preferably the cerium oxide support is in the
form of a washcoat composition deposited on a monolith substrate,
although other forms such as tablets and extrudates can be
used.
[0023] In this copper-based, cerium-oxide supported catalyst, the
platinum group metal is selected from the group consisting of
platinum, palladium, rhodium, osmium, iridium, ruthenium and
combinations thereof. Preferred preferential oxidation catalysts
contain platinum.
[0024] A particularly preferred embodiment of this copper-based,
cerium oxide-supported preferential oxidation catalyst has 5 to 14
wt. % of copper or an oxide thereof dispersed on the cerium oxide
support; and 0.2 to 5 wt. % platinum dispersed on the cerium oxide
support.
[0025] In a method aspect, the invention relates to a process for
selectively oxidizing carbon monoxide from an input gas stream
containing carbon monoxide, oxygen and hydrogen. The process
includes the step of contacting the input gas stream with a
preferential oxidation catalyst.
[0026] In some embodiments of the process there is at least 10% by
volume of hydrogen in the input gas stream. The input gas stream
composition can additionally include steam. In operation, the
process is typically conducted using O.sub.2/CO ratio in the input
gas stream of about 0.25 to 5 at a temperature of about 80 to
160.degree. C.
[0027] In one embodiment, the preferential oxidation catalyst used
in the process contains an oxide support on which is dispersed
copper or an oxide thereof, a platinum group metal, and a reducible
metal oxide. Preferred oxide supports, platinum group metals,
reducible metal oxides, and preferred concentrations are as
described above. The catalyst used in the process is preferably in
the form of particles having a mesh size of 12 or greater, and a
BET surface area of 10 m.sup.2/g or greater, having high mechanical
strength.
[0028] In another embodiment, the process is conducted with the
preferential oxidation catalyst containing a cerium oxide support,
on which is dispersed copper or an oxide thereof and 0.2 wt. % or
more of a platinum group metal. Preferred platinum group metals,
and preferred concentrations therefor, are as described above for
the copper-based, cerium oxide-supported catalyst. In preferred
processes conducted with this catalyst, the catalyst composition is
preferably in the form of a washcoat composition deposited on a
monolith substrate.
[0029] In some embodiments of the process, an input gas stream is
contacted with an article containing two preferential oxidation
catalysts. In the process, the input gas stream is first contacted
with an upstream catalyst to give a first outlet gas stream.
Preferably, the first outlet gas stream contains less than 1000 ppm
of carbon monoxide. The first outlet gas stream is then contacted
with a downstream catalyst to give a second outlet gas stream.
Preferably the second outlet gas stream contains less than 10 ppm
of carbon monoxide.
[0030] The upstream catalyst of the article can be any preferential
oxidation that provides carbon monoxide levels of less than 1000
ppm in the first outlet gas stream. In one embodiment, the
downstream catalyst contains an oxide support (e.g., activated
alumina) on which is dispersed copper or an oxide thereof, a
platinum group metal (e.g., platinum), and a reducible metal oxide
(e.g., cerium oxide). In another embodiment of the article, the
downstream catalyst contains a cerium oxide support, on which is
dispersed copper or an oxide thereof and 0.2 wt. % or more of a
platinum group metal.
[0031] In another aspect, the invention relates to an apparatus for
supplying hydrogen to a PEM fuel cell that incorporate the
preferential oxidation catalysts of the invention. The apparatus
has a hydrocarbon reformer reactor, a water-gas shift reactor, and
a preferential oxidation reactor. The hydrocarbon reformer reactor
is upstream and in train with the water-gas shift reactor, and the
preferential oxidation catalyst is downstream and in train with the
water-gas shift reactor.
[0032] In one embodiment of the apparatus, the preferential
oxidation reactor contains the preferential oxidation catalysts
with oxide supports on which are dispersed copper or an oxide
thereof, a platinum group metal, and a reducible metal oxide. In
another embodiment of the apparatus, the preferential oxidation
reactor contains the preferential oxidation catalysts with a cerium
oxide support, on which is dispersed copper or an oxide thereof and
a platinum group metal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is a depiction of one embodiment of fuel processor
unit for supplying hydrogen to a fuel cell.
[0034] FIG. 2 is a graphic representation of test results for the
reverse water-gas shift properties of an embodiment of Catalyst
B.
[0035] FIG. 3 is a graphic representation of test results obtained
for the carbon monoxide conversion percentage with temperature for
a conventional copper-based catalyst.
DEFINITIONS
[0036] The definitions of certain terms used herein are as
follows:
[0037] "activated alumina" means a high BET surface area alumina,
for example greater than 10 m.sup.2/g, preferably greater than 150
m.sup.2/g having primarily one or more of gamma, theta and delta
aluminas.
[0038] "BET surface area" means the Brunauer, Emmett, Teller method
for determining surface area by N.sub.2 adsorption. Unless
otherwise specifically stated, all references herein to the surface
area refer to the BET surface area.
[0039] "Catalyst A" refers to a catalyst of the invention that
includes a refractory inorganic oxide support (e.g., alumina), a
copper catalytic agent, a reducible metal oxide (e.g., cerium
oxide) and one or more platinum group metals.
[0040] "Catalyst B" refers to a catalyst of the invention that
includes a cerium oxide support, a copper catalytic agent and one
or more platinum group metals.
[0041] "catalytically effective amount" means that the amount of
material present is sufficient to affect the rate of the carbon
monoxide oxidation in the sample being treated.
[0042] "cerium oxide" includes all oxides of cerium including ceria
(CeO.sub.2).
[0043] "cerium oxide support" refers to a particulate support
material wherein cerium oxide is present, preferably in at least a
concentration of 50 wt. % of the total catalyst weight. Other
composite materials may be present along with the cerium oxide,
including for example, other rare earth oxides (e.g., oxides of
lanthanum, praseodymium, neodymium), zirconium oxide and gallium
oxide.
[0044] "copper-based catalyst" refers to a catalyst that includes a
copper catalytic agent. While a platinum group metal or oxide
thereof may be included in the composition, its concentration is
lower, preferably at least 5 times lower on a weight basis than the
copper or oxide thereof.
[0045] "high heat capacity support" means support materials with a
heat capacity that is approximately equal to or, preferably,
greater than that of the reducible metal oxide in the catalyst.
[0046] "high surface area support" means support materials with a
BET surface area that is approximately greater than 10 m.sup.2/g,
preferably greater than 150 m.sup.2/g.
[0047] "incipient wetness impregnation" means the impregnation of
the catalyst support with a volume of metal salt solution
substantially equal to the pore volume of the support material.
[0048] "inlet temperature" shall mean the temperature of the
hydrogen, water, and carbon monoxide stream, test gas, fluid sample
or fluid stream being treated immediately prior to initial contact
of the hydrogen stream, test gas, fluid sample or fluid stream with
a catalyst composition.
[0049] "input gas stream" means a gas stream prior to passing
through a catalytic region or prior to initial contact with a
catalyst composition.
[0050] "in the presence of excess hydrogen" shall mean in the
presence of at least 10% by volume hydrogen.
[0051] "percent by volume" refers to the amount of a particular gas
component of a gas stream, unless otherwise indicated, means the
mole percent of the gas component of the gas stream as expressed as
a volume percent.
[0052] "wt. %." or "percent by weight", means weight percent based
on the weight of an analyte as a percentage of the total catalyst
weight, including the support and any material impregnated therein,
including without limitation the copper catalytic agent and any
metal oxide material impregnated therein. The calculation does not
include the monolith substrate in embodiments where the catalyst is
in the form of a washcoat composition deposited on a monolith
substrate.
[0053] "selectivity" refers to the preferential oxidation of carbon
monoxide in favor of hydrogen.
[0054] "supports" or "catalyst support" refer to particulate
materials that are part of the catalyst composition used to
maintain the surface area of the catalyst. Supports include oxide
supports selected from the group consisting of activated alumina,
zirconia, titania, silica, zeolites and combinations thereof for
Catalyst A. Cerium oxide serves as an effective support for
Catalyst B.
[0055] "VHSV" means volume hourly space velocity; that is, the flow
of a reactant gas in liter per hour per liter of catalyst volume at
standard temperature and pressure. In embodiments of the invention
that include a monolith, the determination includes the total
volume of monolith substrate.
[0056] "WHSV" means weight hourly space velocity; that is the flow
of a reactant gas in liter per hour per kilogram of catalyst.
DETAILED DESCRIPTION OF THE INVENTION
[0057] In accordance with the invention, Applicants have found
copper-based catalysts that selectively catalyze the oxidation of
carbon monoxide in preference to the oxidation of hydrogen in a gas
stream. During operation, the catalysts of the invention maintain
their catalytic oxidation activity at lower temperatures, e.g.,
below 140.degree. C., unlike conventional copper-based catalysts.
The catalysts also achieve higher carbon monoxide conversions at
lower temperatures than conventional copper-based catalysts,
widening the effective temperature window where effective selective
oxidation of carbon monoxide can be conducted. In addition, the
activation temperatures of the catalysts of the invention are lower
than conventional copper-based catalysts. The carbon monoxide
content of hydrogen containing gas streams can be lowered, using
the methods of the invention, to achieve levels below 100 ppm, and
in some cases, below 10 ppm.
[0058] It has been found that the inclusion of low concentrations
of platinum group metal to a copper-based catalyst composition
stabilizes the composition toward exposure to temperature drops
below about 140.degree. C. The improved catalytic stability at
lower temperatures allows the catalysts of the invention to operate
at lower temperatures, where the selectivity for carbon monoxide
oxidation over hydrogen oxidation is thermodynamically more
favorable. The improved carbon monoxide selectivity at lower
temperatures therefore allows achievement of lower levels of carbon
monoxide in the output gas stream.
[0059] While the catalysts of the invention may be used in any
application where it is desirable to remove carbon monoxide from a
hydrogen gas stream, their incorporation into fuel processors that
supply hydrogen to a fuel cell provides significant advantages. In
addition to their ability to achieve minimal concentrations of
carbon monoxide, the catalysts of the invention successfully
operate as effective preferential oxidation catalysts under
conditions typically utilized in fuel processors. In addition, the
copper-based catalysts of the invention also remain active after
temperature drops. This property is desirable for the transient
operation of processors that would be used, for example, in
residential or vehicular fuel cell applications, where power
demands vary considerably.
[0060] While it will be apparent from the discussion regarding the
platinum- and ruthenium-based catalysts above, that certain
platinum group metals can serve as effective preferential oxidation
catalytic agents themselves, their inclusion in the catalysts
compositions is believed to serve primarily as a stabilizing
species to the copper catalytic agents. The relatively low
concentrations of the platinum group metal components in the
catalysts of the invention as compared to the higher concentrations
utilized in platinum metal-based preferential oxidation catalysts
reflect this function. In addition, the utilization of a base
metal, copper, in the catalysts of the invention offers significant
cost advantages over platinum-based preferential oxidation
catalysts. While higher concentrations can be used in the catalyst
composition, lower concentrations of platinum group metals are
preferred to reduce the potential for any reverse water-gas shift
activity, which would limit the level to which carbon monoxide
could be reduced in the output gas stream. In addition, lower
levels of platinum group metals effectively stabilize the catalysts
of the invention to exposure to low temperatures and temperature
drops.
[0061] The catalysts of the invention include a catalyst support,
copper or an oxide thereof, as a catalytic agent, and one or more
platinum group metals. The catalyst can be in any form, including
tablets, extrudates, washcoat compositions deposited on monolith
substrates and high-strength, high heat capacity particulate
catalysts.
[0062] In one embodiment, the invention relates to a preferential
oxidation catalyst that includes a refractory inorganic oxide
support (e.g., alumina), a copper catalytic agent, a reducible
metal oxide (e.g., cerium oxide) and one or more platinum group
metals. For economy of expression this catalyst will be referred to
herein as "Catalyst A".
[0063] In a second embodiment, the invention relates to a
preferential oxidation catalyst that has a cerium oxide support, a
copper catalytic agent and one or more platinum group metals. Here
again, for reasons of convenience, this catalyst will be referred
to herein as "Catalyst B".
[0064] Catalyst A
[0065] Catalyst A contains a refractory inorganic oxide support
(e.g., alumina). Dispersed on the support are a copper catalytic
agent, a reducible metal oxide (e.g., cerium oxide) and one or more
platinum group metals. The catalyst can be in any form including
extrudates, tablets, washcoat compositions deposited on monolith
substrates and high mechanical strength, high heat capacity,
particulate catalysts. Preferred forms of the catalyst are as high
strength, high-heat capacity particulate catalysts.
[0066] Typically, there is at least 5 wt. % of copper in the
catalyst composition for Catalyst A, to serve as a catalytic agent.
Preferably, there is at least 5 to 14 wt. % of copper in the
catalyst composition. The copper catalytic agent can be in the form
of copper (II) oxide (CuO), copper (I) oxide (Cu.sub.2O) or as
metallic copper depending on the conditions that the catalyst is
exposed to. The copper is generally dispersed on the inorganic
oxide support by contacting the support with a water-soluble or
water-dispersible salt of copper for sufficient time to impregnate
the support, followed by a drying step. The support material
containing the copper is then calcined, preferably at a temperature
above about 400.degree. C.
[0067] The catalysts of the invention include a platinum group
metal as a stabilizing species, which is selected from the group
consisting of platinum, palladium, rhodium, iridium and ruthenium.
Preferably, the platinum group metal is platinum, palladium or
rhodium, with platinum being particularly preferred. The platinum
group metals are typically dispersed on the support by contacting
the support with a water-soluble or water-dispersible salt of the
platinum group metal for sufficient time to impregnate the support.
Non-limiting examples of such platinum group metal salts include
nitrates, acetates, alkali-free amine-solubilized platinum
hydroxide, palladium and rhodium nitrate. The supported platinum
group metal is then calcined to fix it to the support as the metal
or as an oxide. Preferably, the amount of the platinum group metal
salts is chosen so that the final concentration of the platinum
group metal on the support is about 0.01 to about 0.5 wt. %, more
preferably 0.05 wt. % to about 0.25 wt. %.
[0068] Suitable reducible metal oxides for Catalyst A include the
oxides of chromium, vanadium, molybdenum, cerium, praseodymium,
neodymium, titanium, nickel, manganese, cobalt, as well as
combinations thereof. Typically, there is at least 10 wt. % of the
reducible metal oxide in the catalyst composition, with levels of
10 to 25 wt. % being preferred.
[0069] A preferred reducible metal oxide is cerium oxide. While
cerium oxide alone serves as the reducible metal oxide component,
in some applications it is desired to include certain composite
materials of cerium oxide. These cerium oxide composites
additionally contain other rare earth metal oxides component such
as oxides of lanthanum, praseodymium, and neodymium. In addition to
these rare earth metal oxide composites, other composite materials
such as zirconia-cerium oxide, gallium oxide-cerium oxide,
titania-cerium oxide are also useful as a reducible metal oxide
components in Catalyst A. In both types of composite materials, it
is believed that the additional component acts as a stabilizer for
the cerium oxide component, although in some cases, the additional
component may also serve to promote the selective oxidation
reaction. In composites comprising cerium oxide with the additional
components, the additional component may comprise up to about 30
wt. % of the reducible metal oxide component of the
composition.
[0070] Inorganic oxide supports for Catalyst A include high surface
area, refractory oxide supports. These refractory oxide supports
include, for example, activated alumina, zirconia, titania, silica,
and zeolites. These supports also include combinations of these
inorganic oxides such as stabilized forms of alumina including
composites of zirconia, or silica with alumina, for example,
alumina-zirconia, silica-alumina, and alumino-silicates.
[0071] In preferred embodiments of Catalyst A, the support is
substantially comprised of alumina which preferably includes the
members of the gamma or activated alumina family, such as gamma and
eta aluminas, and, if present, a minor amount of other refractory
oxides, e.g., up to about 20 wt. % of silica, zirconia, and
titania. Preferably, the activated alumina has a specific surface
area of at least 10 m.sup.2/g. More preferably, the activated
alumina has a specific surface area of at least 150 m.sup.2/g.
[0072] In other preferred embodiments of Catalyst A, the catalyst
supports possess high heat capacity and high mechanical strength.
Copper-based water catalysts are prone to extremely rapid
temperature rises due to the rapid and exothermic oxidation of
carbon monoxide and hydrogen. Such rapid temperature rises can
result in a reduced selectivity for carbon monoxide oxidation. The
reduced selectivity at higher temperatures in turn results in lower
levels of hydrogen in the output stream. In industrial settings,
reactors are equipped with sophisticated process controls and
protocols that can control the temperature rise that occurs upon
oxidation. In fuel cell processors in residential or vehicular
applications, however, such controls and protocols are impractical
to implement. The incorporation into fuel processors of
copper-based preferential oxidation catalysts less prone to these
temperature rises is therefore desirable.
[0073] The high mechanical strength of these preferred supports
yields a system that is resistant to attrition that may occur due
to vibration and other wear mechanisms.
[0074] The high heat capacity, high mechanical strength catalysts
in this embodiment comprise a structurally strong support of any
suitable durable high heat capacity material, such as alumina,
which is in a particulate form preferably having a longest
dimension of about {fraction (1/32)}-inch (0.78 mm) to about
{fraction (1/2)} inch (1.25 cm) in cross section. Preferably, the
support particle is at least {fraction (1/16)}-inch (1.56 mm) in
cross section or, in other terms, has a mesh size of 12 (sieve
opening of 1.52 mm) or above. For example, the support particle
preferably has a mesh size of 12, 11, 10, etc. The catalytic
supports in this embodiment are impregnated, with a suitable
precursor of a reducible metal oxide, the copper catalytic agent
and one or more platinum group metals. Preferred support materials
have a heat capacity that is preferably higher than that of the
reducible metal oxide. Examples of supports are silica, zeolites,
zirconia, titania and alumina. Activated alumina is a particularly
preferred support.
[0075] The high heat capacity particulate support in this preferred
embodiment can take the form of any suitable high strength support
such as a particle, pellet, extrudate, tablet and the like. The
support is preferably in a durable, rigid form. A number of
supports that are suitable for preparing the catalysts of the
invention and practicing the methods of the invention are readily
commercially available. For example, {fraction (1/8)}-inch diameter
alumina particles available from ALCOA as DD-443 (with 327
m.sup.2/g BET surface area measured as received) can be used to
practice the invention. Desirable characteristics for preferred
supports include: having a high mechanical strength (resistance to
crumbling), being readily available; having the capacity for being
impregnated to high loadings with copper catalytic agents,
reducible metal oxides and other catalyst additives; and possessing
a high heat capacity. Supports with a heat capacity of at least the
heat capacity of the reducible metal oxide are preferred. Supports
with a heat capacity greater than the heat capacity of the
reducible metal oxide are particularly preferred.
[0076] Due to their low pyrophoricity, high strength particulate
catalysts having a high heat capacity supports are preferred forms
of Catalyst A. These catalysts can be prepared by first
impregnating the particulate support with the reducible metal oxide
precursor, followed by drying and calcination. For example, in a
preferred preparation calcined {fraction (1/8)}-inch alumina
support particles are impregnated in an aqueous solution of cerium
nitrate (or any other suitable CeO.sub.2 precursor such as cerium
acetate, chloride, etc.). The particles are then dried and calcined
at 500.degree. C. in air to prepare the cerium oxide-impregnated
alumina support (or "CeO.sub.2/alumina particles").
[0077] After preparation of the particulate support with the
reducible metal oxide, the support can be impregnated with a
precursor of the copper catalytic agent. The CeO.sub.2/alumina
particles are impregnated with an aqueous solution of a
water-soluble copper salt, e.g., copper (II) nitrate, at a weakly
acidic pH. The particles are then dried and calcined to provide
CuO/CeO.sub.2/alumina particles. Finally, the CuO/CeO.sub.2/alumina
particles are similarly impregnated with a desired concentration of
a water-soluble salt of the platinum group metal [e.g., alkali-free
amine-solubilized platinum hydroxide] followed by a calcination
step to provide the CuO/CeO.sub.2/alumina particles impregnated
with platinum.
[0078] In other embodiments of Catalyst A, wherein the catalyst is
in the form of washcoat compositions, extrudates and tablets, the
catalyst is preferably formed from powdered supports impregnated
with the copper catalytic agent, the platinum group metal and
reducible metal oxide.
[0079] The impregnated, powdered supports can be prepared by
incipient wetness impregnation of the oxide support (e.g.,
activated alumina) with soluble salts of the reducible metal (e.g.,
cerium). For example, soluble salt forms of the reducible metal
such as acetates, halides, nitrates, sulfates and the like can be
utilized. This step is followed by drying and calcination steps to
fix the reducible metal component as its oxide to the refractory
oxide support.
[0080] The calcined support is then impregnated in analogous
fashion with a desired concentration of a water-soluble salt of the
copper (e.g., copper (II) nitrate) followed by drying and
calcination steps. Finally, the resulting oxide support is
impregnated with a desired concentration of a water-soluble salt of
the platinum group metal (e.g., platinum nitrate) followed by a
calcination step. The calcined, impregnated powdered oxide support
containing the copper catalytic agent, the platinum group metal,
and reducible metal oxide can then be formed into either an
extrudate, tablet, or washcoat composition for deposition on a
monolith substrate.
[0081] In embodiments of the invention wherein the catalyst is in
the form of extrudates, the calcined, powdered oxide support
containing the copper catalytic agent, the platinum group metal,
and reducible metal oxide is typically mixed with a binder and
extrudated through a die of the desired shape. Typical useful
binders include hydrated forms of alumina (e.g., pseudoboehmite),
silica binders, clay binders, zirconia binders and the like.
[0082] Tablets can be prepared by: (1) combining the calcined,
powdered oxide support with a binder; (2) shaping the combined
powder and binder into the desired shape which could include
tablets, pellets, beads, cylinders or hollow cylinders; and (3)
calcining the shaped catalyst.
[0083] Washcoat compositions of the catalyst for deposition on
monolith substrates (or "slurries") are prepared using methods
known in the art. Preferably, the impregnated oxide support is ball
milled as a suspension using sufficient water to prepare a slurry
of a desired concentration. The concentration of the solids in the
washcoat slurry can be used as a method to control the thickness of
the catalyst coating ultimately deposited on the monolith
substrate. For example, increasing the weight percentage of solids
in the aqueous slurry will result in a thicker catalytic coat.
[0084] It is also generally advantageous to prepare slurries having
particles of small particle sizes, e.g., less than 10 .mu.m, to
maximize the surface area of the catalyst upon deposition on the
monolith substrate. Therefore, the particle size distribution of
the slurry is typically measured, and milling is continued until
the desired particle size has been achieved. Here again, binders
are optionally included in the slurries to improve adherence of the
washcoat to the monolith substrate walls.
[0085] The washcoat slurries are deposited on the monolith
substrate by methods well-known to those of ordinary skill. Thus,
for example, a layer of the supported copper catalyst can be
prepared by dipping the substrate in a reservoir containing a
sufficient volume of the slurry so that the substrate is fully
immersed. The coated substrate can be subsequently dried and
calcined.
[0086] As mentioned above, the washcoat catalyst compositions of
the invention are disposed on monolith substrates to form coated
monolith substrates. Although a variety of monolith substrates
could be used, the monolith substrate is preferably of the type
with one or more monolithic bodies having a plurality of finely
divided gas flow passages (channels) extending therethrough.
Preferably, the monolith substrate is of the type having a
plurality of fine, paraliel gas flow passages extending across the
longitudinal axis of the substrate from an inlet or an outlet face,
so that the channels are open to fluid flow therethrough (often
referred to as a "honeycomb substrate"). The passages, which are
essentially straight from the inlet and outlet of the substrates,
are defined by walls on which the catalyst composition can be
coated in washcoat compositions so that the gases flowing through
the passages contact the catalyst material.
[0087] Monolith substrates are commercially available in various
sizes and configurations. The flow passages of the monolithic
substrate are thin-walled channels which can be of any suitable
cross-sectional shape and size such as trapezoidal, rectangular,
square, sinusoidal, hexagonal, oval, circular. Such monolithic
substrates may contain up to about 700 or more flow channels
("cells") per square inch of cross section, although far fewer may
be used. For example, the substrate can have from about 60 to 600,
more usually from about 200 to 400, cells per square inch
("cpsi").
[0088] Various types of materials of construction for monolith
substrates are known. The monolith substrate can be made from a
variety of materials, including metal or ceramic monoliths. In some
embodiments, the monolith substrate can be made from a ceramic
porous material composed of one or more metal oxides, e.g.,
alumina, alumina-silica, alumina-silica-titania, mullite,
cordierite, zirconia, zirconia-ceria, zirconia-spinel,
zirconia-mullite, silicon-carbide, and like. Some non-limiting
examples of ceramic monoliths can include those made of: zirconium,
barium titanate, porcelain, thorium oxide, magnesium oxide,
steatite, boron or silicon carbonates, cordierite-alpha alumina,
silicon nitride, spodumene, alumina-silica magnesia, zircon
silicate, sillimanite, magnesium silicates, zircon, petalite, alpha
alumina and aluminosilicates. One example of a commercially
available material for use as the substrate for the present
invention is cordierite, which is an alumina-magnesia-silica
material.
[0089] The metallic monolith substrate can be a honeycomb substrate
made of a refractory metal such as a stainless steel or other
suitable iron-based corrosion resistant alloys (e.g., iron-chromium
alloy). Metal monoliths can be produced, for example, from alloys
of chromium, aluminum and cobalt, such as those marketed under the
trademark KANTHAL, or those produced from alloys of iron, chromium,
aluminum and yttrium, marketed under the trademark of FECRALLOY.
The metal can also be carbon steel or simple cast iron. Monolith
substrates are typically fabricated from such materials by placing
a flat and a corrugated metal sheet one over the other and rolling
the stacked sheets into a tubular configuration about an axis
parallel to the configurations, to provide a cylindrical-shaped
body having a plurality of fine, parallel gas flow passages, which
can range, typically, from about 200 to about 1,200 per square inch
of face area. Heat exchangers, which are typically formed from
metallic materials, can also be used as the monolith
structures.
[0090] In other embodiments, the monolith substrate can be made of
a ceramic or metal foam. Monolith substrates in the form of foams
are well known in the prior art, e.g., see U.S. Pat. No. 3,111,396
and SAE Technical Paper 971032, entitled "A New Catalyst Support
Structure For Automotive Catalytic Converters" (February,
1997).
[0091] Catalyst B
[0092] Catalyst B contains a copper catalytic agent and one or more
platinum group metals dispersed on a cerium oxide support The
catalyst can be formed as extrudates, tablets and washcoat
compositions deposited on monolith substrates. Preferred forms of
Catalyst B are as washcoat compositions deposited on monolith
substrates.
[0093] Typically, there is at least 5 wt. % of copper in the
Catalyst B composition. Preferably, there is about 5 to 14 wt. % of
copper in Catalyst B. The copper is preferably dispersed on the
inorganic oxide support by contacting the cerium oxide support with
a water-soluble or water-dispersible salt of copper for sufficient
time to impregnate the cerium oxide, followed by a drying step. The
support material containing the copper can then be calcined,
preferably at a temperature above about 400.degree. C.
[0094] Catalyst B of the invention includes a platinum group metal,
which is selected from the group consisting of platinum, palladium,
rhodium, iridium and ruthenium. Preferably, the platinum group
metal is platinum, palladium or rhodium, with platinum being
particularly preferred. Analogous to the methods for preparation of
Catalyst A, the platinum group metals are typically dispersed on
the cerium oxide support by impregnation followed by calcination.
Preferably, the amount of the platinum group metal salts is chosen
so that the final concentration of the platinum group metal on the
support is about 0.2 wt. % to about 5 wt. %, although lower
concentrations of platinum group metals, e.g., 0.2 to 1 wt. %, are
more preferred for reduced material costs.
[0095] Cerium oxide serves as the support of Catalyst B. While
cerium oxide alone can be used for the support, in certain
applications it may be desirable to include additives to the cerium
oxide that stabilize the support. For example, certain composite
materials of cerium oxide that additionally contain other rare
earth metal oxides component such as oxides of lanthanum,
praseodymium, and neodymium are useful. In addition to these rare
earth metal oxide composites, certain composite materials such as
zirconia-cerium oxide, gallium oxide-cerium oxide, titania-cerium
oxide are also useful as composite cerium-oxide support materials
for Catalyst B. In both types of composite materials, it is
believed that the additional component acts as a stabilizer for the
cerium oxide support, although in some cases, the additional
component may also serve to promote the carbon monoxide oxidation.
With composite support materials comprising cerium oxide with
additional stabilizing component, typically the stabilizing
component may comprise up to about 30 wt. %, but preferably less
than 25 wt. % of the cerium oxide support of the composition.
[0096] Washcoat compositions, extrudates and tablets of Catalyst B
are preferably formed from powdered cerium oxide impregnated with
the copper catalytic agent and platinum group metal.
[0097] In a preferred embodiment, Catalyst B is prepared by
impregnating cerium oxide powder with a solution of a water-soluble
salt of copper, e.g., copper (II) nitrate, followed by drying at,
for example 120.degree. C., and calcination at, for example,
500.degree. C. Preferably, the impregnation is accomplished using
incipient wetness impregnation wherein minimal volumes of copper
salt solutions are employed to soak the cerium oxide support. The
resulting cerium oxide support is then impregnated with a
water-soluble salt of a platinum group metal, e.g., platinum
nitrate. A drying and a calcination step follow to provide powdered
Catalyst B. The powdered Catalyst B composition can be formed into
extrudates, tablets and washcoat compositions using the methods
described above for forming the Catalyst A compositions.
[0098] As an alternative to the impregnation method described
above, catalyst B can also be prepared utilizing an aqueous
solution containing a mixture of a water-soluble cerium salt, e.g.,
cerium nitrate, and a water-soluble copper salt, e.g., copper (II)
nitrate. The pH of the solution is then raised by addition of a
base, e.g., sodium carbonate, to the solution to precipitate a
material comprising a mixture of the corresponding hydroxides of
copper and cerium. Preferably the solution is stirred during the
precipitation step. The resulting coprecipitate is collected, dried
and calcined to provide mixed metal oxide material comprising
copper oxide and cerium oxide. Impregnation of the mixed metal
oxide material with a platinum group salt followed by a calcining
of the material can be used to incorporate the platinum group metal
component into the Catalyst B composition.
[0099] The invention also relates to processes for using the
catalysts of the invention, i.e., Catalysts A and B. In a preferred
embodiment, the catalysts of the invention are used as preferential
oxidation catalysts in processes for the selective oxidation of
carbon monoxide in a hydrogen gas stream. For example, the
catalysts of the invention can be incorporated in a reactor that is
charged with an input gas stream containing hydrogen and carbon
monoxide to produce an output hydrogen stream that contains
substantially lower levels of carbon monoxide. For example, levels
below 10 ppm in the output hydrogen gas stream can be achieved
using the selective oxidation processes of the invention.
[0100] The preferential oxidation catalysts of the invention are
reduced (activated) prior to their use in the selective oxidation
reaction. For operational simplicity and decreased startup time, it
is preferred that the process gas itself, containing carbon
monoxide and hydrogen, serve as the reducing gas stream for the
catalysts of the invention.
[0101] The composition of the input gas stream for the process can
vary depending on the source of the hydrogen gas stream. For
instance, in fuel cell applications the input gas stream for the
process could include carbon dioxide, steam, and nitrogen in
addition to hydrogen and carbon monoxide. Minor amounts of
hydrocarbon may also be present.
[0102] The selective oxidation processes of the invention can
accommodate a range of carbon monoxide concentrations in the input
hydrogen stream, depending on the output CO concentration
requirements of a particular application. In fuel cell applications
the concentration of CO in the input hydrogen stream is generally
from 0.05 to 3% by volume.
[0103] Higher levels of carbon monoxide in the input hydrogen gas
stream can be accommodated by variation of other parameters.
Although less desirable from the standpoint of hydrogen fuel
conservation, a higher carbon monoxide conversion can be achieved
at the expense of consuming hydrogen, by increasing the inlet
temperature or increasing the O.sub.2/CO ratio.
[0104] More preferably, one of ordinary skill in the art will
recognize that the process of the invention can conducted by
staging into two or more catalyst beds. In this arrangement, the
input gas stream containing hydrogen and a level of carbon monoxide
would contact the first catalyst bed to produce an intermediate gas
stream that would contain a reduced level of carbon monoxide. The
intermediate gas stream would then contact a second catalyst bed to
produce an outlet gas stream containing still lower levels of
carbon monoxide. Additional catalyst stages could be provided until
the desired carbon monoxide threshold is achieved. Multi-bed
embodiments of the process are described in the Examples
section.
[0105] In fuel cell applications of the inventive process, the
input gas streams typically contain at least 10% by volume of
hydrogen, and more typically from about 40 to 70% on a dry basis in
addition to the carbon monoxide. In addition, there is typically
from about 10 to about 30% by volume added steam (i.e., gaseous
H.sub.2O) in the input hydrogen gas streams in fuel processors.
These levels of steam in the input gas stream can be accommodated
by the process of the invention.
[0106] The molar ratio of oxygen to carbon monoxide in the input
gas stream (O.sub.2/CO ratio) to the process can be adjusted to
optimize carbon monoxide conversion and the selectivity of the
oxidation reaction. For example, one of skill in the art will
recognize that higher O.sub.2/CO ratios favor higher carbon
monoxide conversions. Lower O.sub.2/CO ratios, however, favor more
selective oxidation of carbon monoxide instead of hydrogen. This
parameter can be adjusted according to the particular requirements
of the application. In fuel cell applications, the O.sub.2/CO ratio
is preferably from 0.25 to 5, and more preferably from about 0.5 to
3.
[0107] The reaction temperature of the inventive, selective
oxidation process can be adjusted to optimize the reaction rate,
carbon monoxide conversion and selectivity. For instance, lower
reaction temperatures favor increased selectivity for carbon
monoxide oxidation for a gas compositions at the same space
velocity and O.sub.2/CO ratio. Higher temperatures, however, are
useful for achieving adequate carbon monoxide conversion for input
hydrogen streams at higher space velocities. In fuel cell
applications, preferred operating temperatures for the process of
the invention are from about 80 to 160.degree. C., with a more
preferred range of from about 80 to 130.degree. C.
[0108] Reaction zone pressure is preferably maintained below the
dew point pressure of the reaction mixture. It should be recognized
that lower or higher reaction zone pressures can be used such as
from atmospheric up to about 500 psig.
[0109] Preferably, the selective oxidation process is carried out
in a continuous mode with the reactants being passed over the
catalyst contained in one or more reaction zones. Gaseous hourly
space velocities of about 500 to about 50,000 hr.sup.-1 VHSV
measured on the basis of dry gas under standard conditions are
particularly suitable for most fuel cell operations. In embodiments
wherein the catalysts are in the form of washcoat compositions
deposited on monolith substrates, space velocities of up to 100,000
hr.sup.-1 VHSV can be accommodated. Preferred operating ranges
wherein the catalyst compositions are deposited on a monolith
substrate are 5 to 30,000 hr.sup.-1. One skilled in the art would
recognize that lower gas reactant flow rates favor more complete
carbon monoxide conversion.
[0110] Although the preferential oxidation catalysts of the
invention can be used in any application where it is desired to
remove carbon monoxide from a hydrogen-containing gas stream, a
particularly useful application is in apparatus such as fuel
processors that supply hydrogen to fuel cells. These processors
typically comprise a series of reactors that convert hydrocarbon
fuels (e.g., natural gas, gasoline, fuel oil, liquid petroleum gas,
and the like) into hydrogen fuel. The conversions that take place
in the reactors typically include reforming reactions and water-gas
shift reactions to produce hydrogen. Other reactors and trapping
devices can also be included in the apparatus that reduce unwanted
components in the hydrogen feed streams (e.g., sulfur components),
that are ultimately supplied to the fuel cell. Preferential
oxidation reactors, where the selective oxidation of carbon
monoxide is conducted, is typically performed as a finishing step
to polish the hydrogen feed stream of residual carbon monoxide.
[0111] As seen in a typical fuel processor (1) depicted in FIG. 1,
the hydrocarbon reformer reactor (2) converts hydrocarbons (e.g.,
methane) and steam into hydrogen, carbon monoxide, and carbon
dioxide. For example, the hydrocarbon, methane is converted by the
two reactions below:
CH.sub.4+H.sub.2O.fwdarw.3H.sub.2+CO
CH.sub.4+2H.sub.2O.fwdarw.4H.sub.2+CO.sub.2
[0112] The resulting gas is then reacted in the water-gas shift
reactor (3) to enrich the process gas further in hydrogen, through
the reaction of carbon monoxide with steam. Residual carbon
monoxide in the process stream is then removed by selective
oxidation of carbon monoxide in the preferential oxidation reactor
(4). The resulting process stream comprising high levels of
hydrogen is then supplied to the fuel cell.
[0113] The following examples further illustrate the present
invention, but of course, should not be construed as in any way
limiting its scope. The concentration of specific components of gas
compositions, other than steam, are expressed either as volume
percentages or as parts per million (ppm) on a dry basis. The
concentration steam is indicated as a percentage of added steam.
The flow rate of the test gases were adjusted to achieve the
specified space velocities. The concentration of CO in the output
gas was detected in the examples using an infrared gas analyzer
(Siemens Applied Automation) and the O.sub.2 was detected using an
electrochemical analyzer (Advanced Instruments).
EXAMPLE 1
Preparation of a Copper Ceria-supported Preferential Oxidation
Catalyst Impregnated with 0.5 wt. % Pt. (Exemplifies Preparation of
Catalyst B deposited on a Monolith Substrate Catalyst B1, B2 and
C)
[0114] 205 g of cerium oxide powder (HSA-15 cerium oxide available
from Rhodia, Inc.) was impregnated with 80.6 g of copper nitrate
solution in water using the incipient wetness method. The powder
was calcined using a two-step process; holding the temperature at
120.degree. C. for 2 hours, and then at 500.degree. C. for 2 hours.
The powder was cooled to yield an intermediate powder of 215 g
cerium oxide impregnated with 8 wt. % copper oxide (CuO). This
composition was used to prepare Catalyst C.
[0115] The intermediate powder was then impregnated with an aqueous
solution of alkali-free amine-solubilized platinum hydroxide
containing 1.08 g of platinum. After 1 hour, acetic acid was added
to immobilize the platinum on the cerium oxide support. The
resulting material was calcined using the two step procedure
described above to yield cerium oxide support impregnated with 8
wt. % copper oxide and 0.5 wt. % platinum. This composition is used
to prepare Catalyst B 1.
[0116] A second portion of the intermediate cerium oxide powder
(281 g) impregnated with 8 wt. % copper oxide was prepared as
described above. This portion was impregnated with an aqueous
solution that contained 0.70 g of platinum in the amine-solubilized
platinum hydroxide salt solution, treated with acetic acid (15.15
g), and calcined using the two step calcination procedure to
provide cerium oxide powder impregnated with 8 wt. % copper oxide
and 0.25 wt. % platinum. This composition is used to prepare
Catalyst B2.
[0117] 3 in.times.0.75 in 400 cpsi cordierite monolith pieces were
coated with the two slurries, dried and calcined; a dry gain of
.about.2 g/in.sup.3 was achieved.
[0118] The monolith substrate coated with the catalyst composition
containing 0.5 wt. % Pt is Catalyst B1.
[0119] The monolith substrate coated with the catalyst composition
containing 0.25 wt. % Pt is Catalyst B2.
[0120] The monolith substrate coated with the catalyst composition
without any platinum metal is Catalyst C.
EXAMPLE 2
Determination of CO Conversion using Catalyst B1 (Single Bed)
[0121] Catalyst B1 of Example 1 was tested for its carbon monoxide
conversion and selectivity when exposed to a test gas composition
that modeled a reformate gas stream. The test gas had a dry gas
composition of 0.3% CO, 15% CO.sub.2, 50% H.sub.2 and the balance
was N.sub.2. 25% steam was added as a diluent. Air was added as a
source of oxygen. The catalyst was placed in a quartz tube reactor,
exposed to the test gas, and oxidation began at the minimum
temperature measured, 90.degree. C. The space velocity of the test
gas composition was 15 k/hr. The inlet temperature and the
O.sub.2/CO ratio was adjusted to yield a product gas stable with
respect to CO concentration. The catalyst reached at an inlet
temperature of 140.degree. C. and an O.sub.2/CO ratio of 1.5. The
product gas contained 550 ppm of CO, which is equivalent to a CO
conversion of 82%. 27% of the added O.sub.2 reacted with the
CO.
EXAMPLE 3
Determination of CO Conversion from an Input gas Stream Containing
1.5% CO using the Catalyst of Catalyst B 1 (Two Sequential
Beds)
[0122] Two sections of the B1 catalyst of Example 1 were arrayed in
series with respect to the input gas stream. The temperature of the
first bed was 125.degree. C., while the temperature of the second
catalyst bed was 128.degree. C. The test gas composition in this
example contained 1.5% CO, 15% CO.sub.2, 50% H.sub.2 and the
balance was N.sub.2. 25% steam was added as a diluent. Air was
added as a source of oxygen. The monolith space velocity of the gas
stream was 15 k/hr over the first catalyst bed and 30 k/hr over the
second catalyst bed. The O.sub.2/CO ratio of the initial gas stream
was 0.75. After contact with the first catalyst bed, the CO
concentration in the intermediate gas stream was 5440 ppm. Air was
injected into the intermediate gas stream before contact with the
second catalyst bed to increase the oxygen concentration to 0.39%.
After contact with the second catalyst bed, the CO concentration in
the outlet gas stream was 683 ppm. For the two catalyst stages, the
overall amount of molecular oxygen added was about equimolar to the
initial CO concentration. This outlet CO concentration represented
an 95% reduction in the initial CO concentration across the two
catalyst stages.
EXAMPLE 4
Catalyst B1 Performance as Polishing Bed
[0123] Whereas Examples 2 and 3 serve to demonstrate the
applicability of the Cu/Ce/Pt catalyst (Catalyst B) for the
preferential oxidation of carbon monoxide, a preferred aspect of
the invention is a reliable low-temperature catalyst for achieving
<10 ppm of CO in the presence of levels of both hydrogen and
carbon monoxide found in fuel cell processors. This experiment was
designed to simulate the conditions that a single catalyst bed
would be exposed to as a last bed (also referred to as a "polishing
bed") in a multi-bed system. Experiments were conducted to
determine conditions necessary to achieve a final CO concentration
in the output gas of .about.10 ppm over a wide range of flow
conditions. For the purposes of uniformity, the inlet gas
concentration of CO was kept at 500 ppm. The test gas composition
also contained 15% CO.sub.2, 50% H.sub.2 and the balance was
N.sub.2. 25% steam was added as a diluent. Air was added as a
source of oxygen. Table 1 summarizes the effects of temperature,
space velocity and O.sub.2/CO Ratio on the Catalyst B1 performance
as measured by CO detected in the outlet gas stream.
1TABLE 1 outlet [CO] Monolith VHSV Inlet Temperature O.sub.2/CO
ratio (ppm) 10 k/hr 115 4:1 2.5 10 k/hr 120 4:1 5.5 25 k/hr 120 8:1
5 25 k/hr 120 7.5:1 14 25 k/hr 125 8:1 2.5 25 k/hr 125 5.2:1 4.9 25
k/hr 125 4.5:1 9.0 50 k/hr 125 5:1 10 (550 ppm)* 130 5:1 14 130
5.2:1 12 120 5.2:1 15 125 5.4:1 9 *For technical reasons the CO
concentration in the input gas stream was increased at a space
velocity of 50 k/hr.
[0124] The data shows that the catalyst performs optimally at low
temperature (115.degree. C.) at low space velocity because of the
improved selectivity. As space velocity (.about.25 k/hr) is
increased, a higher temperature is preferred. As a result of higher
operating temperatures, a higher O.sub.2/CO ratio is required to
compensate for operating in a regime with lower selectivity for CO
oxidation.
EXAMPLE 5
Determining the Reverse Water-Gas Shift Liability for Catalyst
[0125] The extent of the catalytic activity for the reverse
water-gas shift was determined using the monolith Catalyst B1 of
Example 1. The monolith catalyst was placed in a quartz reactor
tube and heated to 200.degree. C. The catalyst was cooled with a
test gas stream containing 50% H.sub.2, 15% CO.sub.2, and the
balance N.sub.2 at a space velocity of 17 k/hr. 25% steam was added
a diluent. No CO or oxygen was added to the test gas stream. Any CO
formed was measured in the outlet gas. The data is graphically
presented in FIG. 2. As is shown in FIG. 2, the catalyst exhibits
minimal reverse water-gas shift activity at temperature ranges
useful for the preferential oxidation of CO in hydrogen feed
streams. For example at 140.degree. C., only 5 ppm of CO was
detected in the output gas stream.
EXAMPLE 6
Comparative Example for Operating Ranges with Conventional
Copper-Containing Preferential Oxidation Catalyst (Catalyst C)
[0126] Using the Catalyst C, containing copper oxide (8 wt. % CuO)
on a support of cerium oxide (without any platinum group metal in
the composition, prepared in Example 1), the "T.sub.50" or
temperature at which the CO conversion achieves 50% of the total
input CO was determined. The T.sub.50 was determined using a test
gas stream containing 0.6% CO, 15% CO.sub.2, 50% H.sub.2, and the
balance was N.sub.2. Steam (25%) was added as a diluent. The
determination of the T.sub.50 was conducted using an inlet
temperature range of 110-200.degree. C. The results of the
determination are graphically represented in FIG. 3. As can be seen
in FIG. 3, the T.sub.50 is in excess of 130.degree. C. By
comparison, the T.sub.90 observed for Catalyst B1, containing 0.5
wt. % of platinum, was 90.degree. C. The relatively high activation
temperature for the conventional copper-based Catalyst C requires
is less desirable, due to the increased startup time required for
catalyst activation.
[0127] The catalyst performance of the Catalyst C as a function of
O.sub.2/CO ratio and temperature was also determined using a test
gas composition of 0.5% CO, 15% CO.sub.2, 50% H.sub.2, and the
balance was nitrogen. Steam (25%) was added as a diluent. The
optimal operating temperature was around 150.degree. C. At this
temperature, at an O.sub.2/CO ratio of 1, about 95% of the CO was
oxidized. The catalytic activity, however, dropped to almost nil if
the temperature decreased below 135.degree. C. It is believed that
the deactivation is due to the re-oxidation of the catalyst. The CO
oxidation activity would only return if the catalyst was reheated
in the test gas composition to effect reduction. The example
highlights the narrow temperature window of this conventional
copper-based catalyst relative to the catalysts of the
invention.
EXAMPLE 7
Comparative Example for Operating Ranges with an Iron-Promoted
Platinum on Alumina Catalyst-Preferential Oxidation Catalysts
[0128] For comparative purposes, the catalyst performance of an
platinum-based, iron promoted monolith catalyst (containing a
washcoat with 5 wt. % platinum and 0.3 wt. % iron on alumina as
disclosed in WO 01/17681) as a function of O.sub.2/CO ratio and
temperature was also determined using a test gas composition of
0.3% CO, 15% CO.sub.2, 50% H.sub.2, and the balance was nitrogen.
Steam (25%) was added as a diluent. At a space velocity of 30 k/hr,
an inlet temperature of 90-95.degree. C. and an O.sub.2/CO ratio of
1.4, a CO concentration of 8 ppm was achieved in the output gas
stream.
[0129] When the space velocity of the test gas stream was reduced,
however, it is difficult to achieve a CO concentration of <10
ppm in the outlet gas stream because of reverse water-gas shift
activity, e.g., when the catalyst was tested with the same test gas
composition at a space velocity of 6 k/hr. When the concentration
of CO in the test gas stream was decreased to 750 ppm, the
variation of the O.sub.2/CO ratio from values ranging from 2:1 to
3.8:1 had minimal effect on the concentration of CO in the outlet
gas stream, which remained almost constant at 15 ppm.
[0130] However when the concentration Of CO.sub.2 in the reformate
was reduced from 15 to 5% (dry basis), then the CO in the product
dropped to 5 ppm at an O.sub.2/CO ratio of 2:1. These results are
consistent with the behavior of the reverse water-gas shift
reaction. The data shows that operation of the platinum-based, iron
promoted monolith catalyst preferential oxidation catalyst at low
space velocity and high CO.sub.2 is contraindicated when trying to
achieve 10 ppm of CO in the outlet gas stream.
EXAMPLE 8
Effect of Varying Platinum Metal Concentration on The Performance
of Copper-Based Catalysts
[0131] The effect of varying platinum concentration on Catalyst B
performance was evaluated using a test gas composition containing
360 ppm CO, 15% CO.sub.2, 50% H2, and the balance N.sub.2. Steam
(25%) was added as a diluent. Catalyst B2 (impregnated with 0.25
wt. % Pt) was prepared according to Example 1. The influence of
temperature was evaluated first. At an O.sub.2/CO ratio of 3, good
activity (>90% CO conversion) was observed above 115.degree. C.
at 17 k/hr. The catalyst became stable with a CO concentration of 6
ppm in the outlet gas stream at an O.sub.2/CO ratio of 6.7 at
135.degree. C. At 130.degree. C. with O.sub.2/CO ratios of 5.4 and
6.1, some degree of upward shift in the outlet CO concentration was
observed, a phenomenon normally associated with catalyst
inhibition.
[0132] Another copper-based catalyst was prepared according to
Example 1, with 0.125 wt. % platinum impregnated in the catalyst.
This is catalyst B3. The experiment with the 5 same test gas
composition was repeated with Catalyst B3. At this level, the
platinum was basically innocuous, and activation occurred slowly at
.about.140.degree. C., similar to the data shown in FIG. 2.
[0133] The effect of the concentration of platinum on Catalyst B
performance is summarized in Table 2.
2TABLE 2 Catalyst (% Pt) Temperature for 90% Conversion of CO
Catalyst C (No Platinum) 140.degree. C. Catalyst B3 (0.125 wt. %)
140.degree. C. Catalyst B2 (0.25 wt. %) 115.degree. C. Catalyst B1
(0.50 wt. %) 90.degree. C.
[0134] As can be seen in this Table 2, the addition of as little as
0.25 wt. % of platinum to the copper-cerium oxide catalyst
composition effectively widens the operating window at which
selective CO oxidation can be conducted.
EXAMPLE 9
Preparation of Copper Oxide/Cerium Oxide/Platinum/Alumina
Preferential Oxidation Catalysts (Exemplifies Preparation of High
Heat Capacity, High-Mechanical Strength Embodiments of Catalyst
A)
[0135] To prepare a catalyst wherein the support is alumina, the
reducible metal oxide is ceria and the catalytic agent is CuO,
ceria impregnated alumina support particles were prepared by
incipient wetness impregnation of alumina beads or
particulates.
[0136] {fraction (1/8)}-inch alumina support particles (ALCOA
DD-443) were dried for 2 hours at 200.degree. C. and then calcined
for 2 hours at 500.degree. C. The calcined {fraction (1/8)}-inch
particles were then impregnated (i.e., impregnated at 55% incipient
wetness to obtain about 15 wt. % CeO.sub.2) in an aqueous solution
of cerium nitrate (i.e., Ce(NO.sub.3).sub.3, ; 33.44 g
Ce(NO.sub.3).sub.3 dissolved in 55 g water, per 100 g alumina). The
particles were then dried at 120.degree. C. for 8 hours. The sample
was then calcined at 500.degree. C. for 2 hours.
[0137] The ceria/alumina particles were subsequently impregnated
(i.e., impregnated at 44% incipient wetness to obtain 8.25 wt. %
CuO) with Cu-nitrate solution (i.e., 26.6 mL of 5M
Cu(NO.sub.3).sub.2 solution in 32 mL deionized water) at a pH of 6,
dried at 120.degree. C. for 8 hours and then calcined at
500.degree. C. for 2 hours to prepare catalyst precursor particles
(CuO/ceria/alumina particles).
[0138] The CuO/ceria/alumina particles were then impregnated with
alkali-free amine-solubilized platinum hydroxide. 0.357 g of salt
solution was diluted with 15.75 mL of water and used to impregnate
51.15 g of precursor particles of water was used to prepare a
catalyst containing 0.125 wt. % Pt. The beads were treated with 6.9
mL of acetic acid to immobilize the platinum. After impregnation,
the catalysts was dried at 120.degree. C. for 2 hours then calcined
at 500.degree. C. for 2 hours.
[0139] The resulting alumina particles contained 8.25 wt. % CuO, 15
wt. % CeO.sub.2, and 0.125 wt. % Pt. This is catalyst Al.
[0140] Alumina particles of the same material were also impregnated
above to obtain a catalyst with a higher Pt concentration, i.e.
0.25 wt. %. This catalyst contained 8.25 wt. % CuO, 15 wt. %
CeO.sub.2, and 0.25 wt. % Pt. This is catalyst A2.
[0141] A control catalyst of the same material was prepared without
any added platinum. This catalyst contained 8.25 wt. % CuO, 15 wt.
% CeO.sub.2, and contained no platinum. This is catalyst D.
EXAMPLE 10
Determination of CO Conversion using Catalyst of Example 1
(Exemplifies Catalyst Performance of of High Heat Capacity
High-Mechanical Strength Embodiments of Catalyst A)
[0142] The catalyst performance of Catalyst A1 catalyst of Example
9 was evaluated using a test gas composition containing 5000 ppm
CO, 15% CO.sub.2, 50% H.sub.2, and the balance N.sub.2. Steam (25%)
was added as a diluent. The catalyst beads were placed in a quartz
tube reactor and exposed to the test gas. Oxidation began at the
minimum temperature measured, 90.degree. C. The catalyst
performance was determined as the WHSV was varied from 10-20 k
L/kg.hr. The inlet temperature and the O.sub.2 inlet concentration
was adjusted to yield a product gas stable with respect to outlet
CO concentration.
3TABLE 3 Space Velocity Inlet CO.sub.2 Inlet O.sub.2 Percentage
Outlet CO (WHSV, Inlet Concen- Concen- CO Concen- L/kg .multidot.
hr) Temp. tration tration Conversion tration 10k 110.degree. C.
5000 ppm 7500 ppm 96% 200 ppm 10k 125.degree. C. 5000 ppm 7500 ppm
88% 600 ppm 15k 125.degree. C. 5000 ppm 7000 ppm 90% 500 ppm 20k
125.degree. C. 5000 ppm 4600 ppm 74.5% 1275 ppm 20k 125.degree. C.
5000 ppm 7000 ppm 89.5% 525 ppm
[0143] The data presented in Table 3 exemplifies the locus of
conditions (temperature and space velocity) that are characteristic
of Catalyst A1's performance. For example, at 110.degree. C. and a
space velocity of 10 k L/kg.hr, >95% conversion of the inlet CO
can be achieved.
EXAMPLE 11
Comparative Catalyst Performance of Catalyst A with a Conventional
Platinum-based Catalyst (0.5 wt. % Platinum, 0.03 wt. % iron on
Alumina)
[0144] The catalyst performance of a 0.5 wt. % platinum, 0.03 wt. %
iron on alumina tablets was evaluated for comparative purposes. A
two bed arrangement of the catalyst was used. The first bed
operated at 105.degree. C. near 10 k L/hr.kg with an inlet gas
composition containing 0.5% CO, 0.63% O.sub.2, 50% H.sub.2, 15%
CO.sub.2 and the balance was N.sub.2. Steam (25%) was added as a
diluent. The second bed ran at 85.degree. C. and 10 k L/hr.kg with
0.3% O.sub.2 added. The concentration of CO.sub.2 in the output gas
stream from the first bed was 170 ppm, while the CO.sub.2
concentration in the output gas from the second bed was 6-10
ppm.
[0145] The above experiment was repeated using a first bed
containing Catalyst A2 (with 0.125 wt. % Pt) of Example 9 and the
second bed containing Catalyst A1 (with 0.125 wt. % Pt). The flow
of the test gas was adjusted to achieve the same WHSV as above. At
the same bed operating temperatures as above, the outlet CO
concentration of the first bed was 170 ppm, and the outlet CO
concentration for the second bed was 3.5 ppm. It is particularly
noteworthy that the removal of CO from the hydrogen stream was
achieved using a weighted platinum reduction of 62% for the
copper-based catalysts of the invention as compared to the
conventional platinum-based catalyst.
[0146] The experiment was repeated with both beds containing
Catalyst A1. At the same operating bed temperatures as above, the
outlet CO concentration of the first bed was 120 ppm, and the
outlet CO concentration for the second bed was 3 ppm. In this case
the removal of the CO from the hydrogen stream was achieved using a
weighted platinum reduction of 75% as compared to the conventional
platinum-based catalyst. The platinum group metal reductions
translate into significant savings in material costs.
[0147] The results of the comparison are summarized in Table 4.
4TABLE 4 Outlet CO Outlet CO First Bed Catalyst from First Second
Bed Catalyst from (105.degree. C.) Bed (85.degree. C.) Second Bed
0.5 wt. % Pt/0.03 170 ppm 0.5 wt. % Pt/0.03 6-10 ppm wt.
%/Al.sub.2O.sub.3 wt. %/Al.sub.2O.sub.3 Catalyst A2 170 ppm
Catalyst A1 3.5 ppm (0.25 wt. % Pt) (0.125 wt. % Pt) Catalyst A1
120 ppm Catalyst A1 3 ppm (0.125 wt. % Pt) (0.125 wt. % Pt)
EXAMPLE 12
Comparative Performance of Catalyst D
[0148] The experiment of Example 11 was repeated using a single bed
of Catalyst D of Example 9 (containing no platinum), with only 0.5%
O.sub.2 added to the input gas stream. Catalyst D had no activity
until 140.degree. C. The activity increased with temperature, but
CO conversion never surpassed 60%, compared with the 97%+obtained
for catalyst Al (shown above).
[0149] When this single bed experiment was repeated using Catalyst
A1 of Example 9, containing 0.125 wt. % Pt (with 0.5% CO and
O.sub.2 in the inlet gas), 90% CO conversion was achieved at an
operating temperature of 105.degree. C. The inclusion of platinum,
even at this low level of 0.125 wt. % significantly improves the
percentage of CO converted at lower operating temperatures.
EXAMPLE 13
Comparative Catalyst Performance of Catalyst A1 versus Conventional
Platinum-Based Catalysts at Higher CO Inlet Percentages (i.e., 2%
CO)
[0150] A two bed catalyst arrangement was tested using 0.5 wt. %
platinum, 0.03 wt. % iron on alumina tablets in each bed. A test
gas composition of 2% CO, 15% CO.sub.2, 50% H.sub.2, and the
balance was N.sub.2. Steam (25%) was added as a diluent. The space
velocity for the first bed was 11 k L/kg.hr and 13 k L/kg-hr for
the second bed. Air was added so that the inlet O.sub.2/CO ratio
for the first bed was about 0.45. The inlet temperature was
increased incrementally from 120 to 160.degree. C., primarily
because of evidence of catalyst inhibition at lower temperatures.
The outlet concentration of the first bed was .about.1.2% CO, equal
to a 40% conversion. The O.sub.2 entering the second bed, both from
unreacted O.sub.2 and freshly injected air, was 0.43%. The CO was
further reduced to 4500 ppm in the outlet gas from the second bed
at a temperature of 140.degree. C. The overall CO reduction for the
two beds was .about.77%. Better selectivity was achieved at lower
inlet temperatures, but the catalyst passed increasing amounts of
CO, a sign that the catalyst perfonnance was decaying.
[0151] The experiment was repeated using the Catalyst A1 of Example
9 in each bed. The test gas composition was the same except that
the space velocity was increased for technical reasons. The first
catalyst bed was run at 130.degree. C. and the second bed was run
at 120.degree. C. With the same concentrations of CO and O.sub.2 in
the inlet gas stream, the CO concentration detected in the outlet
gas stream from the first bed was 9200 ppm, while the CO
concentration detected for the second bed was 1850 ppm. The
detected CO concentrations corresponds to a 54% conversion in the
first bed and a 91% conversion after two beds. This is a
significantly better conversion than achieved using the 0.5 wt. %
platinum, 0.03 wt. % iron on alumina catalyst.
[0152] In addition, Catalyst A1 was shown to have a tolerant
operating window. For example, using the test gas composition
described above, containing 2% CO, the first bed was operated at
160.degree. C. to yield an outlet CO concentration from the first
bed of 1% CO. This CO conversion of 50% is still better than that
achieved by the iron promoted, platinum on alumina catalyst. The
result also illustrates the small change in CO selectivity for
Catalyst A1 as a function of temperature. Catalyst A1 was further
tested at 120.degree. C., and the outlet CO concentration decreased
to 8900 ppm, or a CO conversion of 55%.
[0153] In summary, at 2% CO inlet concentration, the preferential
oxidation Catalyst Al, containing 0.125 wt. % Pt, shows superior CO
conversions, with lower material costs than the 0.5 wt. % platinum,
0.03 wt. % iron on alumina tablets. Moreover, the temperature
window for stable operation of the catalyst of the invention is
large.
EXAMPLE 14
[0154] For comparative purposes, an experiment was conducted using
commercially available 0.5% Pt on alumina pellets (Engelhard
Corporation). 24 g of the pellets were loaded into a quartz reactor
and run with a reformate having a dry basis composition of 50%
H.sub.2, 15% CO.sub.2 and balance N.sub.2, with 25% added steam at
a WHSV of 10 k/hr. The first run was conducted with 3000 ppm CO and
an O.sub.2/CO ratio of 1.1. The temperature was increased from 120
to 180.degree. C. In the second run, CO was increased to 5000 ppm,
while the O.sub.2/CO ratio was adjusted to 0.9, a reflection of an
increase in selectivity associated with a higher CO inlet
concentration. Table 5 below demonstrates the influence of
temperature on CO conversion.
5 TABLE 5 Inlet CO Outlet CO Concentration Inlet Concentration % CO
(ppm) Temperature (ppm) Conversion 3000 (with 120.degree. C. 1050
65.0 O.sub.2/CO = 1.1) 130.degree. C. 910 69.7 140.degree. C. 690
77.0 150.degree. C. 420 86.0 160.degree. C. 240 92.0 170.degree. C.
175 94.2 180.degree. C. 175 94.2 5000 (with 150.degree. C. 1550
69.0 O.sub.2/CO = 0.9) 160.degree. C. 1300 74.0 170.degree. C. 1000
80.0 180.degree. C. 700 86.0 190.degree. C. 625 87.5 200.degree. C.
625 87.5
[0155] As is apparent from the data presented in Table 5, 0.5%
Pt/alumina pellets show a high dependence on temperature in the
oxidation of CO. Optimal operating temperature for 0.5% Pt/alumina
pellets were 180-200.degree. C. In comparison, Catalyst A1
(CuO/CeO.sub.2/Pt/alumina beads) run optimally closer to
100.degree. C. as was observed in Examples 10 and 11. For low
temperature applications, such as a preferential oxidation catalyst
polishing bed, the former is not usable because of the propensity
of a platinum-based catalyst to promote reverse water gas shift at
high temperature (at 10 k/hr and 200.degree. C., a value of 275 ppm
CO was observed based on reverse water gas shift)
[0156] With a CO inlet concentration of 5000 ppm, the maximum CO
conversion was 87.5% using 0.5% Pt/alumina pellets. In a similar
experiment performed with catalyst A1 containing 0.125% Pt, CO
outlet concentration was 120 (as described in Example 11).
* * * * *