Heterogeneous catalytic reactor for hydrogen production from formic acid and its use in polymer electrolyte fuel cells

A proof-of-concept prototype of a heterogeneous catalytic reactor has been developed for continuous production of hydrogen via formic acid (FA) dehydrogenation. A laboratory-type polymer electrolyte fuel cell (PEFC) fed with the resulting reformate gas stream (H2 + CO2) was applied to convert chemical energy to electricity. To implement an efficient coupling of the reactor and PEFC, research efforts in interrelated areas were undertaken: (1) solid catalyst development and testing for H2 production; (2) computer modeling of heat and mass transfer to optimize the reactor design; (3) study of compatibility of the reformate gas fuel (H2 + CO2) with a PEFC; and (4) elimination of carbon monoxide impurities via preferential oxidation (PROX). During the catalyst development, immobilization of the ruthenium(II)–meta-trisulfonated triphenylphosphine, Ru-mTPPTS, catalyst on different supports was performed, and this complex, supported on phosphinated polystyrene beads, demonstrated the best results. A validated mathematical model of the catalytic reactor with coupled heat transfer, fluid flow, and chemical reactions was proposed for catalyst bed and reactor design. Measured reactor operating data and characteristics were used to refine modeling parameters. In turn, catalyst bed and reactor geometry were optimized during an iterative adaptation of the reactor and model parameters. PEFC operating conditions and fuel gas treatment/purification were optimized to provide the best PEFC efficiency and lifetime. The low CO concentration (below 5 ppm) in the reformate was ensured by a preferential oxidation (PROX) stage. Stable performance of a 100 W PEFC coupled with the developed reactor prototype was successfully demonstrated.