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infrastructure fuels. Of primary concern is the need to reduce these catalysts in a well-controlled manner that minimizes temperature rise in order to achieve maximum catalyst activity and to prevent the exposure of the catalyst in the reduced state to oxidizing conditions. For example, the CuZn catalysts will sinter if exposed to >270 oC and are pyrophoric when exposed to air in the reduced state. Present commercial catalysts are developed for process plant service where transient conditions are not a concern. There is a need for highly active catalysts that can be supported on a low density monolith that do not require reduction in order to be active and are stable when exposed to oxidizing conditions. ANL is developing a more robust shift catalyst that will work better under transient operating conditions than present catalysts developed for process plant service. The advantage of this catalyst over standard catalysts is that it is air stable, which is needed for many start-up and shutdown cycles. There is a trade-off of a moderate reduction in activity (35). There is also a need to demonstrate that the low-temperature, PROX catalysts have high selectivity toward CO and long term stability. Process/Engineering Development Numerous engineering and process issues are being addressed by fuel processor developers (20, 31, 36). Several major issues are: • As the size of the catalyst bed increases, the segregation within an ATR reactor bed toward over-oxidation and catalyst overheating in the front of the bed, and air starvation and carbon formation in the back end of the bed are important to consider. Maintaining a good temperature distribution in the bed, especially with a large reactor, is identified as one of the challenges facing this approach. • Fuel processor tests have been on the order of 40 hours, although the fuel processors have been tested for 1,000 hours on natural gas. There is a need is to show similar results at realistic operating conditions and further engineering development to enhance the catalyst activity and make the fuel processor lighter and smaller. • There is a need to investigate improved and simplified fuel processor designs. Examples are combining the reformer and the desulfurizer in a single stage to reduce weight and volume, producing an integrated vaporizer design, and designing for a wide variation of fuel vaporization temperatures to allow fuel flexible operation. • Transient issues are important in transport applications and should be addressed early by testing. The challenge is to demonstrate the operation at high sulfur content over the full operating envelope of the vehicle – start-up, transients, shutdown, sulfur spikes in the fuel, etc. using the same processor. Novel Processing Schemes: Various schemes have been proposed to separate the hydrogen-rich fuel in the reformate for cell use or to remove harmful species. At present, the separators are expensive, brittle, require large pressure differential, and are attacked by some hydrocarbons. There is a need to develop thinner, lower pressure drop, low cost membranes that can withstand separation from their support structure under changing thermal loads. Plasma reactors offer independence of reaction chemistry and optimum operating conditions that can be maintained over a wide range of feed rates and H2 composition. These processors have no catalyst and are compact. However, results are preliminary and have only been tested at a laboratory scale. 8-26PDF Image | Fuel Cell Handbook (Seventh Edition)
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