Platinum and rhodium and/or iron containing catalyst formulations for hydrogen generation

Abstract

A method and catalysts for producing a hydrogen-rich syngas are disclosed. According to the method a CO-containing gas contacts a water gas shift (WGS) catalyst, in the presence of water, preferably at a temperature of less than about 450° C. to produce a hydrogen-rich syngas. Also disclosed is a water gas shift catalyst formulated from: a) Pt, its oxides or mixtures thereof, b) at least one of Fe and Rh, their oxides and mixtures thereof, and c) at least one member selected from the group consisting of Sc, Y, Ti, Zr, V, Nb, Ta, Mo, Re, Co, Ni, Pd, Ge, Sn, Sb, La, Ce, Pr, Nd, Sm, and Eu, their oxides and mixtures thereof. The WGS catalyst may be supported on a carrier, such as any one member or a combination of alumina, zirconia, titania, ceria, magnesia, lanthania, niobia, yttria and iron oxide. Fuel processors containing such water gas shift catalysts are also disclosed.

1 . A water gas shift catalyst comprising:
 a) Pt, its oxides or mixtures thereof,   b) at least one member selected from the group consisting of Fe and Rh, their oxides and mixtures thereof, and   c) at least one member selected from the group consisting of Na, K, Sc, Y, Ti, Zr, V, Nb, Ta, Mo, Re, Co, Ni, Pd, Ge, Sn, Sb, La, Ce, Pr, Nd, Sm, and Eu, their oxides and mixtures thereof.   
   
   
       2 . The water gas shift catalyst according to  claim 1 , wherein the water gas shift catalyst comprises:
 a) Pt, its oxides or mixtures thereof,   b) Rh, its oxides or mixtures thereof, and   c) at least one member selected from the group consisting of Ti, Zr, Mo, Co, Ge, Sb, La and Ce, their oxides and mixtures thereof.   
   
   
       3 . The water gas shift catalyst according to  claim 2 , wherein the water gas shift catalyst comprises:
 a) Pt, its oxides or mixtures thereof,   b) Rh, its oxides or mixtures thereof, and   c) one or more of Ge or Sb, its oxides and mixtures thereof.   
   
   
       4 . The water gas shift catalyst according to  claim 2 , wherein the water gas shift catalyst comprises:
 Pt, its oxides or mixtures thereof,   Rh, its oxides or mixtures thereof, and   Mo, its oxides or mixtures thereof.   
   
   
       5 . The water gas shift catalyst according to  claim 2 , wherein the water gas shift catalyst comprises
 Pt, its oxides or mixtures thereof,   Rh, its oxides or mixtures thereof,   Co, its oxides or mixtures thereof, and   one or more of La or Ce, their oxides and mixtures thereof.   
   
   
       6 . The water gas shift catalyst according to  claim 2 , wherein the water gas shift catalyst comprises
 Pt, its oxides or mixtures thereof,   Rh, its oxides or mixtures thereof, and   one or more of Ti, Zr, and Ce, their oxides and mixtures thereof.   
   
   
       7 . The water gas shift catalyst according to  claim 1 , wherein the water gas shift catalyst comprises:
 a) Pt, it oxides or mixtures thereof,   b) Rh and Fe, their oxides and mixtures thereof, and   c) at least one member selected from the group consisting of Co, Pd, Ge, Sb, La, and Ce, their oxides and mixtures thereof.   
   
   
       8 . The water gas shift catalyst according to  claim 7 , wherein the water gas shift catalyst comprises
 Pt, its oxides or mixtures thereof,   Rh, its oxides or mixtures thereof,   Fe, its oxides or mixtures thereof, and   one or more of Ge or Sb, their oxides and mixtures thereof.   
   
   
       9 . The water gas shift catalyst according to  claim 7 , wherein the water gas shift catalyst comprises
 Pt, its oxides or mixtures thereof,   Rh, its oxides or mixtures thereof,   Fe, its oxides or mixtures thereof, and   one or more of Co, La, and Ce, their oxides and mixtures thereof.   
   
   
       10 . The water gas shift catalyst according to  claim 7 , wherein the water gas shift catalyst comprises
 Pt, its oxides or mixtures thereof,   Rh, its oxides or mixtures thereof,   Fe, its oxides or mixtures thereof, and   Pd, its oxides or mixtures thereof.   
   
   
       11 . The water gas shift catalyst according to  claim 1 , wherein the water gas shift catalyst is supported on a carrier comprising at least one member selected from the group consisting of alumina, zirconia, titania, ceria, magnesia, lanthania, niobia, zeolite, perovskite, silica clay, yttria, iron oxide and mixtures thereof. 
   
   
       12 . The water gas shift catalyst according to  claim 11 , wherein the carrier comprises at least one member selected from the group consisting of zirconia, titania and ceria. 
   
   
       13 . The water gas shift catalyst according to  claim 12 , wherein the carrier comprises zirconia. 
   
   
       14 . The water gas shift catalyst according to  claim 1 , wherein the water gas shift catalyst comprises between about 0.01 wt. % to about 10 wt. %, with respect to the total weight of all catalyst components plus the support material, of each Group 8, 9, or 10 element present in the water gas shift catalyst. 
   
   
       15 . The water gas shift catalyst according to  claim 14 , wherein the water gas shift catalyst comprises between about 0.01 wt. % to about 2 wt. %, of each Group 8, 9, or 10 element present in the water gas shift catalyst. 
   
   
       16 . The water gas shift catalyst according to  claim 15 , wherein the water gas shift catalyst comprises between about 0.05 wt. % to about 0.5 wt. % of each Group 8, 9, or 10 element present in the water gas shift catalyst. 
   
   
       17 . A water gas shift catalyst comprising:
 a) Pt, its oxides or mixtures thereof,   b) at least one member selected from the group consisting of Fe and Rh, their oxides and mixtures thereof, and   c) at least one member selected from the group consisting of V, Mo, Co, Ge, Sn, Sb, La, Ce, their oxides and mixtures thereof.   
   
   
       18 . The water gas shift catalyst according to  claim 17 , wherein the water gas shift catalyst comprses:
 a) Pt, its oxides or mixtures thereof,   b) Rh, its oxides or mixtures thereof, and   c) at least one member selected from the group consisting of Mo, Co, Ge, Sb, La and Ce, their oxides and mixtures thereof.   
   
   
       19 . The water gas shift catalyst according to  claim 18 , wherein the water gas shift catalyst comprises:
 a) Pt, its oxides or mixtures thereof,   b) Rh, its oxides or mixtures thereof, and   c) at least one member selected from the group consisting of one or more of Ge or Sb, their oxides and mixtures thereof.   
   
   
       20 . The water gas shift catalyst according to  claim 17 , wherein the water gas shift catalyst comprises:
 a) Pt, it oxides or mixtures thereof,   b) at least one member selected from the group consisting of Rh and Fe, their oxides and mixtures thereof, and   c) at least one member selected from the group consisting of Co, Ge, Sb, La, and Ce, their oxides and mixtures thereof.   
   
   
       21 . The water gas shift catalyst according to  claim 20 , wherein the water gas shift catalyst comprises:
 Pt, its oxides or mixtures thereof,   Rh, its oxides or mixtures thereof,   Fe, its oxides or mixtures thereof, and   at least one member selected from the group consisting of one or more of Ge or Sb, their oxides and mixtures thereof.