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Research & Development Components There are two major areas where fuel processor developers are focusing their research and development efforts, catalyst development and process/engineering development. A smaller, long term effort on novel processing schemes is in the early stages of investigation. Catalyst Development. Performance targets for the fuel processor for transportation fuel cell systems will require that the reforming catalysts used in these processors exhibit a higher activity and better thermal and mechanical stability than reforming catalysts currently used in the production of H2 for large-scale manufacturing processes. To meet these targets, reforming catalysts will have to process the feed at a space velocity of 200,000/hr (based on the volumetric flow of the feed in the gaseous state at 25 °C and 1 atm) with a fuel conversion of >99 percent and a H2 selectivity of >80 percent (moles of H2 in product/moles of H2 “extractable” from the feed), and have a lifetime of 5,000 hr. Given the potential market for transportation applications, many of the major catalyst producers, such as Johnson-Matthey, Engelhard Corporation, and dmc2 division of OM Group, Inc., have begun to develop new reforming catalysts (32). An ANL program is focused on improving long-term stability (minimize deactivation), an important, immediate goal, reducing coke formation for higher hydrocarbons, and improving catalyst sulfur tolerance while addressing cost issues. A major issue is to demonstrate that the catalyst can operate for 40,000+ hours in stationary applications and 4,000+ hours in transportation applications. It is believed that no one has successfully demonstrated these targets. Another issue is that coke formation will be problematic with higher hydrocarbons, especially diesel. Most industrial reforming catalysts are operated steam-rich to minimize coke formation. However, this increases the size of the reformer as well as the energy needed to vaporize the water. This option may not be viable for reformers used with fuel cells. Finally, <20 ppb of S is the target for use with nickel steam reforming catalyst. Most fuels being considered contain either sulfur at the ppm level, such as gasoline, or added as an odorant for safety reasons, such as to natural gas. The ability of the catalyst to process fuels containing ppm levels of sulfur would be beneficial. The ANL catalysts are based on solid oxide fuel cell technology, where a transition metal is supported on an oxide- ion-conducting substrate, such as ceria, zirconia, or lanthanum gallate, that has been doped with a small amount of a non-reducible element, such as gadolinium, samarium, or zirconium. Platinum was the transition metal used in the first generation of the ANL catalyst. Because of concerns over the cost associated with using a precious metal-based catalyst, work has begun on reducing the cost of the catalyst either by replacing Pt with a less expensive non-noble metal or by using a combination of a noble metal, at a considerably lower metal loading, and with a base metal without sacrificing performance. Work is proceeding on catalysts based on Ni, Rh, and combinations of Ni and Rh. Süd-Chemie, Inc. currently produces reforming catalysts based on this technology under a licensing agreement with Argonne (32). There is also a need to develop better water gas shift catalysts (7, 33, 34), especially catalysts that operate at temperatures ranging from 200 to 300 oC. Commercial shift catalysts based on FeCr and CuZn oxides are available, but are not designed for the rapid startups and frequent exposure to oxidizing conditions that will be experienced during normal operation of fuel processors developed for transportation applications. These commercial catalysts have fixed size, high density, and are susceptible to contaminant poisoning by ingredients found in 8-25PDF Image | Fuel Cell Handbook (Seventh Edition)
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