CA2321997A1 - Catalyst - Google Patents
Catalyst Download PDFInfo
- Publication number
- CA2321997A1 CA2321997A1 CA002321997A CA2321997A CA2321997A1 CA 2321997 A1 CA2321997 A1 CA 2321997A1 CA 002321997 A CA002321997 A CA 002321997A CA 2321997 A CA2321997 A CA 2321997A CA 2321997 A1 CA2321997 A1 CA 2321997A1
- Authority
- CA
- Canada
- Prior art keywords
- catalyst
- transition metal
- electrically conductive
- conductive ceramic
- ceramic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/90—Selection of catalytic material
- H01M4/9075—Catalytic material supported on carriers, e.g. powder carriers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/30—Catalysts, in general, characterised by their form or physical properties characterised by their physical properties
- B01J35/391—Physical properties of the active metal ingredient
- B01J35/392—Metal surface area
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/90—Selection of catalytic material
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/90—Selection of catalytic material
- H01M4/92—Metals of platinum group
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/90—Selection of catalytic material
- H01M4/92—Metals of platinum group
- H01M4/925—Metals of platinum group supported on carriers, e.g. powder carriers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/90—Selection of catalytic material
- H01M4/92—Metals of platinum group
- H01M4/921—Alloys or mixtures with metallic elements
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/50—Fuel cells
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Catalysts (AREA)
- Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
Abstract
A catalyst comprises an electrically conductive ceramic substrate having at least one noble metal supported thereupon. The substrate may be a transition metal based ceramic such as a carbide, nitride, boride, or silicide of a transition metal, and the noble metal may comprise a mixture of noble metals. The substrate may comprise a high surface area ceramic. Also disclosed are fuel cells incorporating the catalysts.
Description
This patent application claims priority of provisional patent application 60/075,541 filed February 23, 1998 and entitled "Catalyst."
Field of th_e Invention This invention relates generally to catalysts. More specifically, the invention relates to catalysts of the type comprising at least one noble metal supported on a body of ceramic. Most specifically, the invention relates to catalysts comprised of at least one noble metal supported on an electrically 10 conductive ceramic.
Catalysts are used in a variety of industries and processes to control the rates and/or pathways of chemical reactions. In some instances, catalysts are used to control electrochemical reactions, and such catalysts are referred to as 15 electrocatalysts. The catalyst materials of the present invention may be used in electrochemical and nonelectrochernical processes; however, their high electrical conductivity, stability and resistance to poisoning makes them very useful in electrochemical processes, as for example in fuel cells.
Catalysts frequently are used in harsh environments, and should be 20 chemically stable so as to maintain their reactivity. In those instances where catalysts are used in electrochemical processes, they should also have good electrical conductivity. Noble metals are frequently employed as catalysts, and as generally understood, such metals include platinum, palladium, osmium, iridium, gold, ruthenium and rhodium. In general, the noble metals have good electrical conductivity and are relatively inert; however, such materials are very expensive;
consequently, they are often disposed on a support member. The support member should be chemically stable in harsh environments, and it should have good S electrical conductivity in those instances where the catalyst is being used electrochemically.
In many instances, noble metal catalysts are supported on carbon. Carbon is fairly inert and low in cost; but, the electrical conductivity of carbon is not sufficiently high for many purposes. In addition, carbon does not have good 10 mechanical integrity, and is reactive under certain chemical conditions, particularly highly oxidizing conditions. Carbon supported catalysts are known in the prior art, for example as shown in Patents 5,183,713; 5,024,905 and 4,677,092, and as disclosed therein, such catalysts have been used as electrodes in fuel cells.
15 In some instances, catalysts are supported on ceramic materials; however, ceramics are generally of very low electrical conductivity, which limits the use of the catalysts. PCT publication WO 92/16027 shows noble metal catalysts supported on tungsten oxide. Patent 4,868,841 shows a catalytic body used in carbon dioxide lasers, and comprised of a noble metal catalyst which is supported 20 on an electrically conductive material such as silicon carbide or tin oxide. Patent 5,705,265 shows catalysts comprised of a coating of tin oxide supported on a non-conductive substrate, and further including a noble metal in the coating.
These supports have fairly high electrical resistivities, and are used as resistive heating 3 PCT/US99/03$65 elements for raising the catalyst to a desired working temperature. The disclosed materials are not electrocatalysts, and in general, the electrical conductivity of the disclosed supports is too low to allow these materials to be used as catalysts in electrochemical devices such as fuel cells.
S In some instances, fuel cells are operated on hydrogen which is produced by the reformation of hydrocarbon on alcohol fuels; and such hydrogen is often contaminated with CO, which has been found to be a poison for many prior art catalysts. In other instances, fuel cells are operated on methanol, and CO
poisoning is a problem in methanol cells also. Reformed fuels and methanol are 10 good sources of energy for fuel cells, and there is thus a significant interest in fuel cell catalysts which are CO tolerant.
There is thus a need for a catalytic material which is stable under a wide range of operating conditions, resistant to CO poisoning, and which has good electrical conductivity and sufficient mechanical integrity to allow it to be used in 15 applications such as fuel cells. In addition, the material should be relatively easy to fabricate and low in cost. As will be explained in further detail hereinbelow, the present invention provides a catalyst which is low in cost, stable and has good electrical conductivity.
20 There is disclosed herein a catalyst comprised of a support body, which is a transition metal based, electrically conductive ceramic, and fizrther includes at least one noble metal supported on the support body. In particular embodiments, the transition metal based ceramic comprises a compound of at least one transition metal, the compound being selected from the group consisting of carbides, nitrides, borides, silicides and combinations thereof. In particular embodiments, the ceramic may further include an oxide, oxycarbide or oxynitride therein.
The support member may comprise a high surface area body having a surface area of 5 at least 10 m2/g, and in particular embodiments at least 40 m2/g. The noble metal may comprise a single metal, or an alloy of metals, and one particularly preferred alloy comprises an alloy of platinum and ruthenium. Another preferred alloy comprises platinum and molybdenum. The electrical resistivity of the transition metal based ceramic is, in some embodiments, in the range of 10'6 to 103 ohm-cm.
10 In specifically preferred embodiments, the electrical resistivity of the ceramic is in the range of 10'6 to 1 ohm-cm.
Also disclosed herein is a fuel cell in which at least one electrode thereof includes an electrocatalyst comprised of a support body of an electrically conductive ceramic having at least one noble metal supported thereon.
15 Brief I?eccri~ion of the 1'~rawingc Figure 1 is a set of x-ray diffraction spectra for a catalyst of the present material prepared in accord with Example 4 and for an electrically conductive ceramic support material used in the present invention;
Figure 2 is a polarization curve for a methanol fuel cell electrode of the 20 present invention; and Figure 3 is a polarization curve for a hydrogen fuel cell electrode of the present invention operating in the presence and absence of a CO contaminant.
Detailed Description of the Invention The catalytic material of the present invention comprises at least one noble metal disposed upon an electrically conductive ceramic support. Within the context of this disclosure, electrically conductive materials shall refer to those 5 materials having an electrical resistivity in the range of 10-6 to 103 ohm-cm. Most preferably, the electrical resistivity of the supports of the present invention are in the range of 106 to 1 ohm-cm, particularly in those instances where the catalyst is used as an electrocatalytic material, as for example in a fuel cell, battery or chemical reactor.
10 The electrically conductive ceramic of the present invention is preferably a transition metal based ceramic, and this designation refers to the fact that the ceramic material includes a compound of at least one transition metal therein.
Such compounds are preferably selected from the group consisting of carbides, nitrides, borides, silicides and combinations thereof.
15 The transition metals used in the present invention can be any transition metal, but will most preferably comprise those transition metals from Groups III-VII of the periodic table. In particular embodiments, the transition metal is preferably selected from Groups IV-VI, and some specifically preferred transition metal compounds are based on Group V-VI elements.
20 The support members of the present invention may also include some portion of oxygen therein either as a metallic oxide or a metallic oxycarbide, oxyboride, oxysilicide or oxynitride. The oxygen compound comprises a minor component of the ceramic support, and as such the support is distinguished from WO 99/42213 PCTNS99/03$65 oxide based materials such as tin oxide and alumina. Typically the oxygen component comprises less than 15 weight percent of the bulk ceramic. As will be explained in greater detail hereinbelow, the presence of an oxygen component such as the oxide, oxycarbide, oxyboride, oxysilicide or oxynitride on the support 5 diminishes the poisoning effects of CO poisoning on many noble metal catalysts.
The oxygen component can be present throughout the bulk of the support;
however, it can be disposed only on the surface of the support, and will still manifest its beneficial effects. The oxygen component may be incorporated during the fabrication of the bulk material of the support, or it may be a native 10 oxide, oxycarbide or oxynitride formed on the surface of the support by post-fabrication treatment, as for example by exposure to the ambient atmosphere, or by exposure to more extreme oxidizing conditions, as for example treatment with high temperature or pressure gasses; or by treatment with plasmas, or oxidizing solutions such as oxygenated water, hydrogen peroxide or the like. In some 15 instances, the oxygen component can be formed by anodic oxidation. The oxygen component may form a thin, continuous covering on the entirety of the surface of the substrate, or may comprise isolated domains.
The ceramics used in the present invention are preferably of relatively high surface area, and typically have a surface area of at least 10 MZ/g, and in a 20 preferred embodiment have a surface area of at least 40 MZ/g.
The ceramic support body of the present invention permits a higher loading of electrocatylitic noble metal, as compared to support bodies of the prior art.
This permits the use of thinner layers of electrocatalysts in applications such as fuel cell membrane electrode assemblies; which in turn provides higher power density by avoiding fuel transport limitations in the electrocatalyst layer.
The support body of the present invention also provides for a better dispersion of the noble metal which leads to its more efficient utilization. While not wishing to be 5 bound by speculation, it is believed that another advantage of the present invention is that the oxygen sites on the electrically conductive ceramic enhance the carbon monoxide resistance of the catalyst, thereby minimizing the amount of ruthenium or other noble metal which prior art catalysts require to achieve carbon monoxide tolerance.
10 The present invention may be employed with any noble metal catalyst system. As is known in the art, such catalyst systems comprise one or more noble metals, which may also be used in combination with non-noble metals. One particularly preferred noble metal material comprises an alloy of platinum and ruthenium. Other particularly preferred catalyst systems comprise alloys of 15 platinum and molybdenum; platinum and tin; and platinum, ruthenium and osmium. Other noble metal catalytic systems known and available to those of skill in the art may be similarly employed in the present invention.
In view of the disclosure and discussion presented herein, various methods for the fabrication of electrically conductive ceramic substrates, and various 20 methods for the disposition of noble metal materials onto the substrates will be apparent to one of skill in the art, and the present invention is not limited to any specific fabrication method. The fabrication of high surface area transition metal based ceramic materials are disclosed in U.S. Patent 5,680,292; U.S. Patent 5,837,630 and U.S. Patent Application 08/818,337, the disclosures of which are all incorporated herein by reference. In those instances where high surface area substrates are not required, other bulk fabrication techniques such as sintering, hot pressing and the like may be employed. The noble metal can be deposited onto 5 the substrate by a variety of techniques including chemical precipitation, sputtering, evaporation, plasma vapor deposition, chemical vapor deposition, photochemical decomposition and the like.
The following examples are illustrative of particular embodiments of the present invention, but are not meant to be limitations upon the practice thereof.
In this example, a catalyst comprising platinum supported on a high surface area tungsten carbide body was prepared. The total weight of the catalyst was approximately 20 grams, and the platinum content was approximately 10 weight percent.
15 Five grams of hexachioroplatinic acid was dissolved in 200 ml of methanol. The amount of chloroplatinic acid was chosen to be equivalent to 2 grams of platinum metal, and the specific amount of the chloroplatinic acid employed in a particular synthesis will depend upon the degree of its hydration.
A high surface area tungsten carbide ceramic powder was prepared according to 20 the methods disclosed in Patent 5,680,292, and 18 grams of this material was added directly to the chloroplatinic acid solution. The mixture was sonicated for 10 minutes and then refluxed for 4 hours. The methanol was removed by evaporation at room temperature under vacuum to produce a dry powder comprising a platinum compound adsorbed on the support material. This powder was transferred to a horizontal pyrolysis tube of fused silica and a mixture of 10%
hydrogen and 90% nitrogen was flowed through the tube. The tube was initially heated to 110°C for 20 minutes to remove any residual moisture or solvent from 5 the powder. The temperature of the tube was then raised to 400°C, and this elevated temperature maintained for 2 hours, during which time reduction of the chloroplatinic acid took place. Following the reduction step, the atmosphere flowing through the tube was switched to a passivating atmosphere comprised of I % oxygen with the balance being nitrogen. The temperature of the tube was 10 adjusted to 350°C and maintained thereat for 30 minutes, after which the tube was allowed to cool to room temperature while the flow of the passivation atmosphere was maintained. It is believed that some oxides are formed during the passivation step.
This resulted in the production of approximately 20 grams of catalyst 15 comprising a tungsten carbide substrate having approximately 10% platinum thereon. The particle size of the platinum was measured to be about 4 nanometers, based upon x-ray diffraction line widths.
In this example, 5 grams of hexachloroplatinic acid was dissolved in 100 20 ml of water in a 500 ml Erlenmeyer flask. This was mixed with 200 ml of 2%
sodium hydroxide and the mixed solution heated to 60°C to produce a hexahydroxoplatinate solution. About 18 grams of tungsten carbide support material, prepared in accord with the previous example, was added to the hexahydroxoplatinate solution to produce a slurry. The slurry was sonicated for 10 minutes, after which the flask was topped with a watch glass, and the slurry mixture boiled on a hot plate, with stirring, for 30 minutes. After 30 minutes, the watch glass was removed and boiling maintained until a significant amount of the 5 water evaporated and a thick slurry was left. Drying was continued under vacuum at 60°C to produce a dried powder which was washed three times with pure water, in a Buchner filnnel, to remove any soluble materials. The resultant catalyst was redried, and comprised approximately 9% by weight of platinum, with the platinum having an average particle size of about 3 nm, as based upon x-ray 10 diffraction line widths.
In this example, a platinum-ruthenium alloy catalyst was prepared by a method generally similar to that of Example 1. 1.3 grams of hexachloroplatinic acid and .5 grams of ruthenium trichloride were dissolved in 100 ml of methanol.
1 S 3.5 grams of tungsten carbide was added to the solution as in Example 1, and filrther processing proceeded accordingly.
This procedure produced approximately 5 grams of platinum-ruthenium alloy catalyst in which the atomic ratio of platinum to ruthenium was approximately 1:1. X-ray absorption spectroscopy showed that the resulting 20 catalyst contained some platinum oxide and some ruthenium oxide.
A series of catalysts prepared by the method of claim 3 were tested for their ability to facilitate the oxidation of hydrogen, in a fuel cell application, at room temperatures, both in the presence and absence of carbon monoxide. In this experimental series, 20 milligrams of the catalyst was dispersed in 0.5 ml of a 0.2% isopropyl alcohol solution of a perfluorosulfonic acid membrane material of the type sold under the trademark Nafion~ by the DuPont Corporation.
Dispersion was accomplished by sonication and overnight stirring. 50 microliters 5 of the dispersion was spread onto a hydrophobic layer of carbon having an area of 1 square centimeter, and the alcohol evaporated off to produce a fuel cell electrode incorporating the catalyst material. The thus prepared electrodes were employed as anodes in a gas fed type electrode/cell assembly in which the electrode was in contact with a 0.5 M sulfuric acid electrolyte. A feed comprised of either pure 10 hydrogen or hydrogen with 200 ppm of carbon monoxide was flowed through the back of the electrode at a flow rate of 70 ml/min. Polarization was measured at various current densities without iR correction at room temperature, and the results thereof are summarized hereinbelow.
15 Current density Pt-Ru/tungsten carbide lAm e~re,~ No O mV vs RHEI 7.00 n~nm~ ,~mV vs IZHFI
0.01 4 4 0.05 42 300 0.1 87 550 20 0.2 172 320 0.4 320 380 This experimental series demonstrates that the materials of the present invention can be advantageously employed in a practical fuel cell.
Polarization in the presence of CO is low, even when the fuel cell is operated at room 25 temperature. Polarization will be even lower when the cell is at its normal, elevated operating temperature. It is also significant that the amount of noble metal in the catalyst of the present invention is only about half that of a conventional cell, yet performance is excellent. Thus this experiment shows that the present invention provides a catalyst for fuel cells which is very tolerant of CO
and utilizes lowered loadings of noble metal.
5 ExamPl~4 In this example, catalysts composed of platinum and/or platinum-ruthenium alloy particles dispersed on tungsten carbide supports were prepared by a method generally similar to that described by Watanabe et al. (Watanabe, M.;
Uchida, M.; Motoo, S. J. Electroanal. Chem. 1987, 229, 395-406). 122 mg of Pt 10 in the form of hexachloroplatinic acid solution was added to 800 mL of deionized water. 15 grams of sodium bisulfate was added to the solution, and the pH was adjusted to between 3 and S with drops of 10% sodium carbonate solution drop-wise, with 10% sodium carbonate added simultaneously to maintain a solution pH
of 3-5. When the solution was titrated with peroxide to the equivalence point (no 15 changes in pH were observed with the addition of hydrogen peroxide), peroxide addition was ceased. 185 mg of ruthenium chloride dissolved in 50 mL of deionized water was added slowly to the solution. For pure Pt catalysts, the addition of ruthenium is omitted. An additional 15 mL of 30% hydrogen peroxide was then added slowly to the solution after reaching the equivalence point.
The 20 solution was covered to prevent evaporation and stirred for 2 hours to reduce peroxide concentrations to desired levels.
1.8 g of tungsten carbide was washed ultrasonically in deionized water and added to a 2 liter flask containing 1 liter of deionized water. The noble metal 13 PCTNS99/03$65 solution prepared above was added to the flask, which was then purged for at least 14 hours with hydrogen gas while under magnetic stirring.
The procedure produced approximately 2 grams of supported platinum ruthenium alloy catalyst with platinum and ruthenium percentages of 6.2 and 3.1 5 percent by weight, respectively, as determined by atomic absorption spectroscopy.
As described in detail below, X-ray diffraction patterns exhibited no signs of platinum-ruthenium particles, suggesting noble metal particles sizes of less than 2-3 nm.
The catalytic materials prepared by the methods of Example 4 described 10 above were first characterized by analyzing the metallic contents using atomic absorption spectrophotometry and then by x-ray diffraction techniques. X-ray diffraction patterns of the support carbide and the Pt-Ru dispersed catalyst were compared to examine the dispersion quality as shown in Fig. 1. The diffraction peaks as indicated in the figure correspond essentially to tungsten carbides such 15 as WC and WC,_x. No peaks associated with Pt02 or Ru02 (the fine metallic particles are expected to exist as oxide forms) have been detected with significant intensities. Following the relationship (Cullity, Elements of X-ray Diffraction, Addison-Wesley, Reading, MA 1978) between the peak width of a diffraction peak and the average crystallite size d, 20 d = 0.9~./(B cos $B) where ~., B and $ denote x-ray wavelength, full width at the half maximum of the diffraction peak and Bragg angle, respectively, fairly well defined peaks with a peakwidth 3-5 ° would be observed for a Pt crystallite size nm in the same signal-to-noise spectra as in Fig. 1 since the cross-section for Pt is much larger than the support material. Hence the absence of such peak suggests that the noble metal particles are very small, i.e. less than 3nm in diameter or they form amorphous phases. If the platinum clusters are assumed spherical, the specific surface area S can be estimated based on a simple geometric model. Dispersion of clusters 3nm in average diameter would give a specific surface area of ca. 90 m2/g.
The catalysts prepared in this example were evaluated in a gas fed fuel cell using methods generally similar to those employed in testing the Example 3 materials. 20 mg of the catalyst was dispersed in O.SmI of 0.2% Nafion-isopropyl 10 alcohol in a small vial by sonication and stirring overnight. This catalyst dispersion of 50 ~1 which corresponds to 2 mg catalyst/cm2 was spread onto a hydrophobic carbon layer of 1 cm2. Anodic currents were measured for the gas phase reactants using a gas-fed type electrode/cell assembly in which the electrode was in contact with O.SM sulfuric acid and the gas was supplied to the back of the 15 electrode. Electrodes prepared in this fashion were tested for methanol oxidation at room temperature. A typical polarization curve is shown in Fig. 2.
Electrodes were also tested for hydrogen oxidation at room temperatures with and without 200 ppm carbon monoxide in the hydrogen stream at 70 ml/min. The results are displayed in Fig. 3. These experiments illustrate yet other methods for fabricating 20 the catalytic materials of the present invention, and the utility of these materials in both hydrogen and methanol fuel cells.
Examgl~
Procedures as set forth above can be implemented using support ceramics other than the tungsten carbide. Comparable results will also be achieved using carbides of other transition metals such as niobium, vanadium, and molybdenum.
5 Similarly, nitride, boride and silicide based ceramics will also produce good catalyst materials. In some instances, mixed compounds can be employed as the conductive ceramic. For example, a ceramic having the composition W.9Ni.~C has been found to produce a very good substrate for a catalyst used in fuel cells.
Other techniques can be employed for the deposition of the noble metals 10 onto the support material. For example, in one other process, chloroplatinic acid is dissolved in water to produce a solution having a pH of approximately 2, a molar excess of sodium bisulfite (based on the molarity of platinum) is added to the solution raising the pH to approximately 3.5. In those instances where a second metal such as ruthenium is to be incorporated, a salt of the metal, such as 15 ruthenium trichloride, is dissolved in water and added in the appropriate amounts to the platinum solution. The pH of the solution is then adjusted to approximately 5, by the addition of sodium carbonate. A 30% solution of hydrogen peroxide is then added to the solution, dropwise, to adjust the pH to between 3 and 5.
Excess peroxide is to be avoided since it can decompose certain ceramic support bases;
20 therefore, the solution is allowed to stand for several hours to permit excess peroxide to decompose, and the ceramic support material is then added to the solution to produce a slurry. The ceramic/solution slurry is stirred and hydrogen bubbled therethrough for at least 10 hours to reduce the metallic ions into free metal which precipitates onto the surface of the ceramic.
It has been found that when mixed platinum ruthenium catalysts are being employed, the platinum:ruthenium ratio for the ceramic supported catalyst of the 5 present invention may differ from those previously employed for platinum:
ruthenium supported on carbon. This may be due to differences in catalytic activities of the resultant material due to electronic and/or structural contributions induced by interactions between the noble metals and the support material. In general, the optimum Pt:Ru ratio for the catalysts of the present invention is 10 expected to be greater than that reported for carbon supported Pt:Ru catalysts.
Other noble metals may be similarly deposited onto ceramic support substrates utilizing the techniques disclosed hereinabove. Also, as previously noted, other techniques may be employed to deposit the noble metal onto the support structure.
In view of the foregoing, it will be appreciated that the present invention 15 is directed to catalysts comprised of one or more noble metals supported on an electrically conductive ceramic substrate, which is most preferably a transition metal containing ceramic substrate. The substrates may be prepared by a number of techniques known in the prior art, and the noble metals may be likewise deposited onto the substrates by art known techniques. In view of the foregoing, 20 many modifications and variations of the present invention will be apparent to one of skill in the art. The foregoing discussion, description and examples is meant to be illustrative of some specific embodiments of the invention, but is not a WO 99/42213 PCT/US99/03$65 limitation upon the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention.
Field of th_e Invention This invention relates generally to catalysts. More specifically, the invention relates to catalysts of the type comprising at least one noble metal supported on a body of ceramic. Most specifically, the invention relates to catalysts comprised of at least one noble metal supported on an electrically 10 conductive ceramic.
Catalysts are used in a variety of industries and processes to control the rates and/or pathways of chemical reactions. In some instances, catalysts are used to control electrochemical reactions, and such catalysts are referred to as 15 electrocatalysts. The catalyst materials of the present invention may be used in electrochemical and nonelectrochernical processes; however, their high electrical conductivity, stability and resistance to poisoning makes them very useful in electrochemical processes, as for example in fuel cells.
Catalysts frequently are used in harsh environments, and should be 20 chemically stable so as to maintain their reactivity. In those instances where catalysts are used in electrochemical processes, they should also have good electrical conductivity. Noble metals are frequently employed as catalysts, and as generally understood, such metals include platinum, palladium, osmium, iridium, gold, ruthenium and rhodium. In general, the noble metals have good electrical conductivity and are relatively inert; however, such materials are very expensive;
consequently, they are often disposed on a support member. The support member should be chemically stable in harsh environments, and it should have good S electrical conductivity in those instances where the catalyst is being used electrochemically.
In many instances, noble metal catalysts are supported on carbon. Carbon is fairly inert and low in cost; but, the electrical conductivity of carbon is not sufficiently high for many purposes. In addition, carbon does not have good 10 mechanical integrity, and is reactive under certain chemical conditions, particularly highly oxidizing conditions. Carbon supported catalysts are known in the prior art, for example as shown in Patents 5,183,713; 5,024,905 and 4,677,092, and as disclosed therein, such catalysts have been used as electrodes in fuel cells.
15 In some instances, catalysts are supported on ceramic materials; however, ceramics are generally of very low electrical conductivity, which limits the use of the catalysts. PCT publication WO 92/16027 shows noble metal catalysts supported on tungsten oxide. Patent 4,868,841 shows a catalytic body used in carbon dioxide lasers, and comprised of a noble metal catalyst which is supported 20 on an electrically conductive material such as silicon carbide or tin oxide. Patent 5,705,265 shows catalysts comprised of a coating of tin oxide supported on a non-conductive substrate, and further including a noble metal in the coating.
These supports have fairly high electrical resistivities, and are used as resistive heating 3 PCT/US99/03$65 elements for raising the catalyst to a desired working temperature. The disclosed materials are not electrocatalysts, and in general, the electrical conductivity of the disclosed supports is too low to allow these materials to be used as catalysts in electrochemical devices such as fuel cells.
S In some instances, fuel cells are operated on hydrogen which is produced by the reformation of hydrocarbon on alcohol fuels; and such hydrogen is often contaminated with CO, which has been found to be a poison for many prior art catalysts. In other instances, fuel cells are operated on methanol, and CO
poisoning is a problem in methanol cells also. Reformed fuels and methanol are 10 good sources of energy for fuel cells, and there is thus a significant interest in fuel cell catalysts which are CO tolerant.
There is thus a need for a catalytic material which is stable under a wide range of operating conditions, resistant to CO poisoning, and which has good electrical conductivity and sufficient mechanical integrity to allow it to be used in 15 applications such as fuel cells. In addition, the material should be relatively easy to fabricate and low in cost. As will be explained in further detail hereinbelow, the present invention provides a catalyst which is low in cost, stable and has good electrical conductivity.
20 There is disclosed herein a catalyst comprised of a support body, which is a transition metal based, electrically conductive ceramic, and fizrther includes at least one noble metal supported on the support body. In particular embodiments, the transition metal based ceramic comprises a compound of at least one transition metal, the compound being selected from the group consisting of carbides, nitrides, borides, silicides and combinations thereof. In particular embodiments, the ceramic may further include an oxide, oxycarbide or oxynitride therein.
The support member may comprise a high surface area body having a surface area of 5 at least 10 m2/g, and in particular embodiments at least 40 m2/g. The noble metal may comprise a single metal, or an alloy of metals, and one particularly preferred alloy comprises an alloy of platinum and ruthenium. Another preferred alloy comprises platinum and molybdenum. The electrical resistivity of the transition metal based ceramic is, in some embodiments, in the range of 10'6 to 103 ohm-cm.
10 In specifically preferred embodiments, the electrical resistivity of the ceramic is in the range of 10'6 to 1 ohm-cm.
Also disclosed herein is a fuel cell in which at least one electrode thereof includes an electrocatalyst comprised of a support body of an electrically conductive ceramic having at least one noble metal supported thereon.
15 Brief I?eccri~ion of the 1'~rawingc Figure 1 is a set of x-ray diffraction spectra for a catalyst of the present material prepared in accord with Example 4 and for an electrically conductive ceramic support material used in the present invention;
Figure 2 is a polarization curve for a methanol fuel cell electrode of the 20 present invention; and Figure 3 is a polarization curve for a hydrogen fuel cell electrode of the present invention operating in the presence and absence of a CO contaminant.
Detailed Description of the Invention The catalytic material of the present invention comprises at least one noble metal disposed upon an electrically conductive ceramic support. Within the context of this disclosure, electrically conductive materials shall refer to those 5 materials having an electrical resistivity in the range of 10-6 to 103 ohm-cm. Most preferably, the electrical resistivity of the supports of the present invention are in the range of 106 to 1 ohm-cm, particularly in those instances where the catalyst is used as an electrocatalytic material, as for example in a fuel cell, battery or chemical reactor.
10 The electrically conductive ceramic of the present invention is preferably a transition metal based ceramic, and this designation refers to the fact that the ceramic material includes a compound of at least one transition metal therein.
Such compounds are preferably selected from the group consisting of carbides, nitrides, borides, silicides and combinations thereof.
15 The transition metals used in the present invention can be any transition metal, but will most preferably comprise those transition metals from Groups III-VII of the periodic table. In particular embodiments, the transition metal is preferably selected from Groups IV-VI, and some specifically preferred transition metal compounds are based on Group V-VI elements.
20 The support members of the present invention may also include some portion of oxygen therein either as a metallic oxide or a metallic oxycarbide, oxyboride, oxysilicide or oxynitride. The oxygen compound comprises a minor component of the ceramic support, and as such the support is distinguished from WO 99/42213 PCTNS99/03$65 oxide based materials such as tin oxide and alumina. Typically the oxygen component comprises less than 15 weight percent of the bulk ceramic. As will be explained in greater detail hereinbelow, the presence of an oxygen component such as the oxide, oxycarbide, oxyboride, oxysilicide or oxynitride on the support 5 diminishes the poisoning effects of CO poisoning on many noble metal catalysts.
The oxygen component can be present throughout the bulk of the support;
however, it can be disposed only on the surface of the support, and will still manifest its beneficial effects. The oxygen component may be incorporated during the fabrication of the bulk material of the support, or it may be a native 10 oxide, oxycarbide or oxynitride formed on the surface of the support by post-fabrication treatment, as for example by exposure to the ambient atmosphere, or by exposure to more extreme oxidizing conditions, as for example treatment with high temperature or pressure gasses; or by treatment with plasmas, or oxidizing solutions such as oxygenated water, hydrogen peroxide or the like. In some 15 instances, the oxygen component can be formed by anodic oxidation. The oxygen component may form a thin, continuous covering on the entirety of the surface of the substrate, or may comprise isolated domains.
The ceramics used in the present invention are preferably of relatively high surface area, and typically have a surface area of at least 10 MZ/g, and in a 20 preferred embodiment have a surface area of at least 40 MZ/g.
The ceramic support body of the present invention permits a higher loading of electrocatylitic noble metal, as compared to support bodies of the prior art.
This permits the use of thinner layers of electrocatalysts in applications such as fuel cell membrane electrode assemblies; which in turn provides higher power density by avoiding fuel transport limitations in the electrocatalyst layer.
The support body of the present invention also provides for a better dispersion of the noble metal which leads to its more efficient utilization. While not wishing to be 5 bound by speculation, it is believed that another advantage of the present invention is that the oxygen sites on the electrically conductive ceramic enhance the carbon monoxide resistance of the catalyst, thereby minimizing the amount of ruthenium or other noble metal which prior art catalysts require to achieve carbon monoxide tolerance.
10 The present invention may be employed with any noble metal catalyst system. As is known in the art, such catalyst systems comprise one or more noble metals, which may also be used in combination with non-noble metals. One particularly preferred noble metal material comprises an alloy of platinum and ruthenium. Other particularly preferred catalyst systems comprise alloys of 15 platinum and molybdenum; platinum and tin; and platinum, ruthenium and osmium. Other noble metal catalytic systems known and available to those of skill in the art may be similarly employed in the present invention.
In view of the disclosure and discussion presented herein, various methods for the fabrication of electrically conductive ceramic substrates, and various 20 methods for the disposition of noble metal materials onto the substrates will be apparent to one of skill in the art, and the present invention is not limited to any specific fabrication method. The fabrication of high surface area transition metal based ceramic materials are disclosed in U.S. Patent 5,680,292; U.S. Patent 5,837,630 and U.S. Patent Application 08/818,337, the disclosures of which are all incorporated herein by reference. In those instances where high surface area substrates are not required, other bulk fabrication techniques such as sintering, hot pressing and the like may be employed. The noble metal can be deposited onto 5 the substrate by a variety of techniques including chemical precipitation, sputtering, evaporation, plasma vapor deposition, chemical vapor deposition, photochemical decomposition and the like.
The following examples are illustrative of particular embodiments of the present invention, but are not meant to be limitations upon the practice thereof.
In this example, a catalyst comprising platinum supported on a high surface area tungsten carbide body was prepared. The total weight of the catalyst was approximately 20 grams, and the platinum content was approximately 10 weight percent.
15 Five grams of hexachioroplatinic acid was dissolved in 200 ml of methanol. The amount of chloroplatinic acid was chosen to be equivalent to 2 grams of platinum metal, and the specific amount of the chloroplatinic acid employed in a particular synthesis will depend upon the degree of its hydration.
A high surface area tungsten carbide ceramic powder was prepared according to 20 the methods disclosed in Patent 5,680,292, and 18 grams of this material was added directly to the chloroplatinic acid solution. The mixture was sonicated for 10 minutes and then refluxed for 4 hours. The methanol was removed by evaporation at room temperature under vacuum to produce a dry powder comprising a platinum compound adsorbed on the support material. This powder was transferred to a horizontal pyrolysis tube of fused silica and a mixture of 10%
hydrogen and 90% nitrogen was flowed through the tube. The tube was initially heated to 110°C for 20 minutes to remove any residual moisture or solvent from 5 the powder. The temperature of the tube was then raised to 400°C, and this elevated temperature maintained for 2 hours, during which time reduction of the chloroplatinic acid took place. Following the reduction step, the atmosphere flowing through the tube was switched to a passivating atmosphere comprised of I % oxygen with the balance being nitrogen. The temperature of the tube was 10 adjusted to 350°C and maintained thereat for 30 minutes, after which the tube was allowed to cool to room temperature while the flow of the passivation atmosphere was maintained. It is believed that some oxides are formed during the passivation step.
This resulted in the production of approximately 20 grams of catalyst 15 comprising a tungsten carbide substrate having approximately 10% platinum thereon. The particle size of the platinum was measured to be about 4 nanometers, based upon x-ray diffraction line widths.
In this example, 5 grams of hexachloroplatinic acid was dissolved in 100 20 ml of water in a 500 ml Erlenmeyer flask. This was mixed with 200 ml of 2%
sodium hydroxide and the mixed solution heated to 60°C to produce a hexahydroxoplatinate solution. About 18 grams of tungsten carbide support material, prepared in accord with the previous example, was added to the hexahydroxoplatinate solution to produce a slurry. The slurry was sonicated for 10 minutes, after which the flask was topped with a watch glass, and the slurry mixture boiled on a hot plate, with stirring, for 30 minutes. After 30 minutes, the watch glass was removed and boiling maintained until a significant amount of the 5 water evaporated and a thick slurry was left. Drying was continued under vacuum at 60°C to produce a dried powder which was washed three times with pure water, in a Buchner filnnel, to remove any soluble materials. The resultant catalyst was redried, and comprised approximately 9% by weight of platinum, with the platinum having an average particle size of about 3 nm, as based upon x-ray 10 diffraction line widths.
In this example, a platinum-ruthenium alloy catalyst was prepared by a method generally similar to that of Example 1. 1.3 grams of hexachloroplatinic acid and .5 grams of ruthenium trichloride were dissolved in 100 ml of methanol.
1 S 3.5 grams of tungsten carbide was added to the solution as in Example 1, and filrther processing proceeded accordingly.
This procedure produced approximately 5 grams of platinum-ruthenium alloy catalyst in which the atomic ratio of platinum to ruthenium was approximately 1:1. X-ray absorption spectroscopy showed that the resulting 20 catalyst contained some platinum oxide and some ruthenium oxide.
A series of catalysts prepared by the method of claim 3 were tested for their ability to facilitate the oxidation of hydrogen, in a fuel cell application, at room temperatures, both in the presence and absence of carbon monoxide. In this experimental series, 20 milligrams of the catalyst was dispersed in 0.5 ml of a 0.2% isopropyl alcohol solution of a perfluorosulfonic acid membrane material of the type sold under the trademark Nafion~ by the DuPont Corporation.
Dispersion was accomplished by sonication and overnight stirring. 50 microliters 5 of the dispersion was spread onto a hydrophobic layer of carbon having an area of 1 square centimeter, and the alcohol evaporated off to produce a fuel cell electrode incorporating the catalyst material. The thus prepared electrodes were employed as anodes in a gas fed type electrode/cell assembly in which the electrode was in contact with a 0.5 M sulfuric acid electrolyte. A feed comprised of either pure 10 hydrogen or hydrogen with 200 ppm of carbon monoxide was flowed through the back of the electrode at a flow rate of 70 ml/min. Polarization was measured at various current densities without iR correction at room temperature, and the results thereof are summarized hereinbelow.
15 Current density Pt-Ru/tungsten carbide lAm e~re,~ No O mV vs RHEI 7.00 n~nm~ ,~mV vs IZHFI
0.01 4 4 0.05 42 300 0.1 87 550 20 0.2 172 320 0.4 320 380 This experimental series demonstrates that the materials of the present invention can be advantageously employed in a practical fuel cell.
Polarization in the presence of CO is low, even when the fuel cell is operated at room 25 temperature. Polarization will be even lower when the cell is at its normal, elevated operating temperature. It is also significant that the amount of noble metal in the catalyst of the present invention is only about half that of a conventional cell, yet performance is excellent. Thus this experiment shows that the present invention provides a catalyst for fuel cells which is very tolerant of CO
and utilizes lowered loadings of noble metal.
5 ExamPl~4 In this example, catalysts composed of platinum and/or platinum-ruthenium alloy particles dispersed on tungsten carbide supports were prepared by a method generally similar to that described by Watanabe et al. (Watanabe, M.;
Uchida, M.; Motoo, S. J. Electroanal. Chem. 1987, 229, 395-406). 122 mg of Pt 10 in the form of hexachloroplatinic acid solution was added to 800 mL of deionized water. 15 grams of sodium bisulfate was added to the solution, and the pH was adjusted to between 3 and S with drops of 10% sodium carbonate solution drop-wise, with 10% sodium carbonate added simultaneously to maintain a solution pH
of 3-5. When the solution was titrated with peroxide to the equivalence point (no 15 changes in pH were observed with the addition of hydrogen peroxide), peroxide addition was ceased. 185 mg of ruthenium chloride dissolved in 50 mL of deionized water was added slowly to the solution. For pure Pt catalysts, the addition of ruthenium is omitted. An additional 15 mL of 30% hydrogen peroxide was then added slowly to the solution after reaching the equivalence point.
The 20 solution was covered to prevent evaporation and stirred for 2 hours to reduce peroxide concentrations to desired levels.
1.8 g of tungsten carbide was washed ultrasonically in deionized water and added to a 2 liter flask containing 1 liter of deionized water. The noble metal 13 PCTNS99/03$65 solution prepared above was added to the flask, which was then purged for at least 14 hours with hydrogen gas while under magnetic stirring.
The procedure produced approximately 2 grams of supported platinum ruthenium alloy catalyst with platinum and ruthenium percentages of 6.2 and 3.1 5 percent by weight, respectively, as determined by atomic absorption spectroscopy.
As described in detail below, X-ray diffraction patterns exhibited no signs of platinum-ruthenium particles, suggesting noble metal particles sizes of less than 2-3 nm.
The catalytic materials prepared by the methods of Example 4 described 10 above were first characterized by analyzing the metallic contents using atomic absorption spectrophotometry and then by x-ray diffraction techniques. X-ray diffraction patterns of the support carbide and the Pt-Ru dispersed catalyst were compared to examine the dispersion quality as shown in Fig. 1. The diffraction peaks as indicated in the figure correspond essentially to tungsten carbides such 15 as WC and WC,_x. No peaks associated with Pt02 or Ru02 (the fine metallic particles are expected to exist as oxide forms) have been detected with significant intensities. Following the relationship (Cullity, Elements of X-ray Diffraction, Addison-Wesley, Reading, MA 1978) between the peak width of a diffraction peak and the average crystallite size d, 20 d = 0.9~./(B cos $B) where ~., B and $ denote x-ray wavelength, full width at the half maximum of the diffraction peak and Bragg angle, respectively, fairly well defined peaks with a peakwidth 3-5 ° would be observed for a Pt crystallite size nm in the same signal-to-noise spectra as in Fig. 1 since the cross-section for Pt is much larger than the support material. Hence the absence of such peak suggests that the noble metal particles are very small, i.e. less than 3nm in diameter or they form amorphous phases. If the platinum clusters are assumed spherical, the specific surface area S can be estimated based on a simple geometric model. Dispersion of clusters 3nm in average diameter would give a specific surface area of ca. 90 m2/g.
The catalysts prepared in this example were evaluated in a gas fed fuel cell using methods generally similar to those employed in testing the Example 3 materials. 20 mg of the catalyst was dispersed in O.SmI of 0.2% Nafion-isopropyl 10 alcohol in a small vial by sonication and stirring overnight. This catalyst dispersion of 50 ~1 which corresponds to 2 mg catalyst/cm2 was spread onto a hydrophobic carbon layer of 1 cm2. Anodic currents were measured for the gas phase reactants using a gas-fed type electrode/cell assembly in which the electrode was in contact with O.SM sulfuric acid and the gas was supplied to the back of the 15 electrode. Electrodes prepared in this fashion were tested for methanol oxidation at room temperature. A typical polarization curve is shown in Fig. 2.
Electrodes were also tested for hydrogen oxidation at room temperatures with and without 200 ppm carbon monoxide in the hydrogen stream at 70 ml/min. The results are displayed in Fig. 3. These experiments illustrate yet other methods for fabricating 20 the catalytic materials of the present invention, and the utility of these materials in both hydrogen and methanol fuel cells.
Examgl~
Procedures as set forth above can be implemented using support ceramics other than the tungsten carbide. Comparable results will also be achieved using carbides of other transition metals such as niobium, vanadium, and molybdenum.
5 Similarly, nitride, boride and silicide based ceramics will also produce good catalyst materials. In some instances, mixed compounds can be employed as the conductive ceramic. For example, a ceramic having the composition W.9Ni.~C has been found to produce a very good substrate for a catalyst used in fuel cells.
Other techniques can be employed for the deposition of the noble metals 10 onto the support material. For example, in one other process, chloroplatinic acid is dissolved in water to produce a solution having a pH of approximately 2, a molar excess of sodium bisulfite (based on the molarity of platinum) is added to the solution raising the pH to approximately 3.5. In those instances where a second metal such as ruthenium is to be incorporated, a salt of the metal, such as 15 ruthenium trichloride, is dissolved in water and added in the appropriate amounts to the platinum solution. The pH of the solution is then adjusted to approximately 5, by the addition of sodium carbonate. A 30% solution of hydrogen peroxide is then added to the solution, dropwise, to adjust the pH to between 3 and 5.
Excess peroxide is to be avoided since it can decompose certain ceramic support bases;
20 therefore, the solution is allowed to stand for several hours to permit excess peroxide to decompose, and the ceramic support material is then added to the solution to produce a slurry. The ceramic/solution slurry is stirred and hydrogen bubbled therethrough for at least 10 hours to reduce the metallic ions into free metal which precipitates onto the surface of the ceramic.
It has been found that when mixed platinum ruthenium catalysts are being employed, the platinum:ruthenium ratio for the ceramic supported catalyst of the 5 present invention may differ from those previously employed for platinum:
ruthenium supported on carbon. This may be due to differences in catalytic activities of the resultant material due to electronic and/or structural contributions induced by interactions between the noble metals and the support material. In general, the optimum Pt:Ru ratio for the catalysts of the present invention is 10 expected to be greater than that reported for carbon supported Pt:Ru catalysts.
Other noble metals may be similarly deposited onto ceramic support substrates utilizing the techniques disclosed hereinabove. Also, as previously noted, other techniques may be employed to deposit the noble metal onto the support structure.
In view of the foregoing, it will be appreciated that the present invention 15 is directed to catalysts comprised of one or more noble metals supported on an electrically conductive ceramic substrate, which is most preferably a transition metal containing ceramic substrate. The substrates may be prepared by a number of techniques known in the prior art, and the noble metals may be likewise deposited onto the substrates by art known techniques. In view of the foregoing, 20 many modifications and variations of the present invention will be apparent to one of skill in the art. The foregoing discussion, description and examples is meant to be illustrative of some specific embodiments of the invention, but is not a WO 99/42213 PCT/US99/03$65 limitation upon the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention.
Claims (22)
1. A catalyst comprising:
a support body comprised of a transition metal based, electrically conductive ceramic; and at least one noble metal supported upon said support body.
a support body comprised of a transition metal based, electrically conductive ceramic; and at least one noble metal supported upon said support body.
2. A catalyst as in claim 1, wherein said transition metal based, electrically conductive ceramic comprises a compound of at least one transition metal, said compound being selected from the group consisting of carbides, nitrides, borides, silicides, and combinations thereof.
3. A catalyst as in claim 2, wherein said transition metal is selected from Groups III-VII of the periodic table.
4. A catalyst as in claim 2, wherein said transition metal is selected from Groups IV-VI of the periodic table.
5. A catalyst as in claim 2, wherein said transition metal is selected from Groups V-VI of the periodic table.
6. A catalyst as in claim 2, wherein said transition metal based, electrically conductive ceramic further includes an oxygen component selected from the group consisting of: oxides, oxynitrides, oxycarbides, oxyborides and combinations thereof.
7. A catalyst as in claim 6, wherein said oxygen component is disposed upon at least a portion of the surface of said transition metal based, electrically conductive ceramic.
8. A catalyst as in claim 1, wherein said transition metal based, electrically conductive ceramic has a surface area of at least 10 m2/g.
9. A catalyst as in claim 1, wherein said transition metal based, electrically conductive ceramic has a surface area of at least 40 m2/g.
10. A catalyst as in claim 1, wherein said noble metal is selected from the group consisting of Pt, Pd, Os, Ir, Ru, Ag, Rh, and combinations thereof.
11. A catalyst as in claim 1, wherein said noble metal comprises a mixture of platinum and ruthenium.
12. A catalyst as in claim 1, wherein said noble metal comprises a mixture of platinum and molybdenum.
13. A catalyst as in claim 1, wherein the electrical resistivity of said transition metal based, electrically conductive ceramic is in the range of 10 -6 to 10 3 ohm-cm.
14. A catalyst as in claim 1, wherein the electrical resistivity of said transition metal based, electrically conductive ceramic is in the range of 10 -6 to 1 ohm-cm.
15. A fuel cell wherein at least one electrode thereof includes an electrocatalyst, said electrocatalyst comprising:
a support body comprised of an electrically conductive ceramic; and at least one noble metal supported on said support body.
a support body comprised of an electrically conductive ceramic; and at least one noble metal supported on said support body.
16. A fuel cell as in claim 15, wherein said electrically conductive ceramic is a compound of at least one transition metal, said compound being selected from the group consisting of carbides, nitrides, borides, silicides, and combinations thereof.
17. A fuel cell, as in claim 15, wherein said electrically conductive ceramic has a surface area of at least 10 m2/g.
18. A fuel cell as in claim 15, wherein the electrical resistivity of said ceramic is in the range of 10 -6 to 10 3 ohm-cm.
19. A fuel cell as in claim 15, wherein the electrical resistivity of said ceramic is in the range of 10-6 to 1 ohm-cm.
20. A catalyst comprising:
a support body comprised of a compound of at least one transition metal, said compound being selected from the group consisting of carbides, nitrides, borides, silicides, and combinations thereof; said support body having an electrical resistivity in the range of 10-6 to 10 3 ohm-cm, and a surface area of at least 10 m2/g; and at least one noble metal supported upon said support body.
a support body comprised of a compound of at least one transition metal, said compound being selected from the group consisting of carbides, nitrides, borides, silicides, and combinations thereof; said support body having an electrical resistivity in the range of 10-6 to 10 3 ohm-cm, and a surface area of at least 10 m2/g; and at least one noble metal supported upon said support body.
21. A catalyst as in claim 20, wherein said support body further includes an oxygen compound disposed at least on the surface thereof.
22. A catalyst as in claim 21, wherein said oxygen compound is derived from said at least one transition metal.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US7554198P | 1998-02-23 | 1998-02-23 | |
| US60/075,541 | 1998-02-23 | ||
| US09/253,965 US6297185B1 (en) | 1998-02-23 | 1999-02-22 | Catalyst |
| US09/253,965 | 1999-02-22 | ||
| PCT/US1999/003865 WO1999042213A1 (en) | 1998-02-23 | 1999-02-23 | Catalyst |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2321997A1 true CA2321997A1 (en) | 1999-08-26 |
Family
ID=26756993
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002321997A Abandoned CA2321997A1 (en) | 1998-02-23 | 1999-02-23 | Catalyst |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US6297185B1 (en) |
| EP (1) | EP1060019B1 (en) |
| AT (1) | ATE306985T1 (en) |
| AU (1) | AU2689499A (en) |
| CA (1) | CA2321997A1 (en) |
| DE (1) | DE69927793T2 (en) |
| WO (1) | WO1999042213A1 (en) |
Families Citing this family (57)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19914814C1 (en) * | 1999-03-31 | 2000-12-14 | Siemens Ag | Recombination device and method for the catalytic recombination of hydrogen and / or carbon monoxide with oxygen in a gas mixture |
| FR2796312B1 (en) * | 1999-07-16 | 2001-09-07 | Atofina | SUPPORTED METAL CATALYST, ITS PREPARATION AND ITS APPLICATIONS IN THE DIRECT MANUFACTURE OF HYDROGEN PEROXIDE |
| CZ301735B6 (en) | 1999-10-08 | 2010-06-09 | Fuelcell Energy, Ltd. | Composite electrodes for solid state electrochemical devices |
| US6482763B2 (en) * | 1999-12-29 | 2002-11-19 | 3M Innovative Properties Company | Suboxide fuel cell catalyst for enhanced reformate tolerance |
| DE10048844A1 (en) * | 2000-10-02 | 2002-04-11 | Basf Ag | Process for the production of platinum metal catalysts |
| DE10104226A1 (en) * | 2001-01-31 | 2002-08-01 | Basf Ag | Core / shell catalyst bodies |
| US6939640B2 (en) * | 2001-09-21 | 2005-09-06 | E. I. Dupont De Nemours And Company | Anode electrocatalysts for coated substrates used in fuel cells |
| WO2003058734A1 (en) * | 2002-01-03 | 2003-07-17 | Neah Power Systems, Inc. | Porous fuel cell electrode structures having conformal electrically conductive layers thereon |
| US20030166972A1 (en) * | 2002-02-20 | 2003-09-04 | Regents Of The University Of California Office Of Technology Licensing | Process for production of formaldehyde from dimethyl ether |
| JP3587199B2 (en) * | 2002-05-29 | 2004-11-10 | 日本電気株式会社 | Fuel cell catalyst-carrying particles, composite electrolytes using the same, catalyst electrodes, fuel cells, and methods for producing them |
| CA2486354C (en) * | 2002-06-12 | 2013-03-12 | Sulzer Metco (Canada) Inc. | Hydrometallurgical process for production of supported catalysts |
| JP2004079244A (en) * | 2002-08-12 | 2004-03-11 | Toshiba Corp | Fuel cell catalyst and fuel cell |
| JP2006526880A (en) * | 2003-05-30 | 2006-11-24 | イー・アイ・デュポン・ドウ・ヌムール・アンド・カンパニー | Components using fuel cells and their high metal-to-support ratio catalysts |
| US7677254B2 (en) * | 2003-10-27 | 2010-03-16 | Philip Morris Usa Inc. | Reduction of carbon monoxide and nitric oxide in smoking articles using iron oxynitride |
| US6897178B1 (en) * | 2003-10-31 | 2005-05-24 | The Regents Of The University Of Michigan | Carbide/nitride based fuel processing catalysts |
| JP4198582B2 (en) * | 2003-12-02 | 2008-12-17 | 独立行政法人科学技術振興機構 | Tantalum oxynitride oxygen reduction electrocatalyst |
| US20050209098A1 (en) * | 2004-03-19 | 2005-09-22 | De Nora Elettrodi S.P.A. | Carbon supported metal alloy catalysts and method for the manufacturing thereof |
| US20070131541A1 (en) * | 2004-10-26 | 2007-06-14 | Kohichi Miyashita | Electrolysis vessel and apparatus for generating electrolyzed water |
| US7713910B2 (en) * | 2004-10-29 | 2010-05-11 | Umicore Ag & Co Kg | Method for manufacture of noble metal alloy catalysts and catalysts prepared therewith |
| WO2006119147A2 (en) * | 2005-05-02 | 2006-11-09 | General Motors Global Technology Operations, Inc. | Supports for fuel cell catalysts |
| US7767330B2 (en) * | 2005-05-04 | 2010-08-03 | Gm Global Technology Operations, Inc. | Conductive matrices for fuel cell electrodes |
| US7951749B2 (en) * | 2005-10-11 | 2011-05-31 | The Regents Of The University Of Michigan | Enhancing hydrogen spillover and storage |
| US20070092784A1 (en) * | 2005-10-20 | 2007-04-26 | Dopp Robert B | Gas diffusion cathode using nanometer sized particles of transition metals for catalysis |
| US20080280190A1 (en) * | 2005-10-20 | 2008-11-13 | Robert Brian Dopp | Electrochemical catalysts |
| US20070128499A1 (en) * | 2005-11-18 | 2007-06-07 | Campbell Stephen A | Catalyst for fuel cells |
| US7833645B2 (en) | 2005-11-21 | 2010-11-16 | Relion, Inc. | Proton exchange membrane fuel cell and method of forming a fuel cell |
| US20080032174A1 (en) * | 2005-11-21 | 2008-02-07 | Relion, Inc. | Proton exchange membrane fuel cells and electrodes |
| US20070161501A1 (en) * | 2006-01-10 | 2007-07-12 | Atomic Energy Council - Institute Of Nuclear Energy Research | Method for making carbon nanotube-supported platinum alloy electrocatalysts |
| US7955755B2 (en) | 2006-03-31 | 2011-06-07 | Quantumsphere, Inc. | Compositions of nanometal particles containing a metal or alloy and platinum particles |
| US20070227300A1 (en) * | 2006-03-31 | 2007-10-04 | Quantumsphere, Inc. | Compositions of nanometal particles containing a metal or alloy and platinum particles for use in fuel cells |
| US7691775B2 (en) * | 2006-05-04 | 2010-04-06 | The Regents Of The University Of Michigan | Reducible oxide based catalysts |
| US20080020924A1 (en) * | 2006-07-19 | 2008-01-24 | Atomic Energy Council-Institute Of Nuclear Energy Research | Method of fabricating platinum alloy electrocatalysts for membrane fuel cell applications |
| WO2008121128A2 (en) * | 2006-10-16 | 2008-10-09 | Direct Carbon Technologies, Llc | Multi-functional cermet anodes for high temperature fuel cells |
| US8383293B2 (en) * | 2006-11-22 | 2013-02-26 | GM Global Technology Operations LLC | Supports for fuel cell catalysts based on transition metal silicides |
| US8026020B2 (en) | 2007-05-08 | 2011-09-27 | Relion, Inc. | Proton exchange membrane fuel cell stack and fuel cell stack module |
| US9293778B2 (en) | 2007-06-11 | 2016-03-22 | Emergent Power Inc. | Proton exchange membrane fuel cell |
| US8003274B2 (en) | 2007-10-25 | 2011-08-23 | Relion, Inc. | Direct liquid fuel cell |
| KR101202130B1 (en) | 2008-02-20 | 2012-11-15 | 쇼와 덴코 가부시키가이샤 | Catalyst carrier, catalyst and method for producing the same |
| CN101648140B (en) * | 2008-08-14 | 2011-09-07 | 中国科学院大连化学物理研究所 | Tungsten carbide catalyst, preparation thereof and application thereof in reaction for preparing glycol from cellulose |
| CN102132447B (en) * | 2008-08-25 | 2013-12-18 | 3M创新有限公司 | Fuel cell nanocatalyst with voltage reversal tolerance |
| DE102008047142A1 (en) * | 2008-09-12 | 2010-04-15 | o.m.t. Oberflächen- und Materialtechnologie GmbH | Catalytic material, useful as electrodes in electric energy producing fuel cells, comprises at least one metal-carbon compound or metal oxide-carbon compound, where the metal is e.g. nickel, cobalt vanadium and chromium |
| US9006133B2 (en) | 2008-10-24 | 2015-04-14 | Oned Material Llc | Electrochemical catalysts for fuel cells |
| CN102049273B (en) | 2009-10-27 | 2013-05-01 | 中国科学院大连化学物理研究所 | Mesoporous carbon-supported tungsten carbide catalyst and preparation and application thereof |
| CN102190562B (en) | 2010-03-17 | 2014-03-05 | 中国科学院大连化学物理研究所 | A kind of method of polyhydroxy compound preparation ethylene glycol |
| KR101688524B1 (en) * | 2010-07-30 | 2016-12-22 | 삼성전자주식회사 | Electrode catalyst for fuel cell, membrane electrode assembly and fuel cell including the same, and method of preparing electrode catalyst for fuel cell |
| WO2013035191A1 (en) | 2011-09-09 | 2013-03-14 | 昭和電工株式会社 | Catalyst layer for fuel cells and use thereof |
| CN103506144B (en) * | 2012-06-27 | 2017-07-28 | 浙江工业大学 | The tungsten carbide of core shell structure/platinum composite and its preparation and application |
| US9762848B2 (en) * | 2013-03-15 | 2017-09-12 | Google Inc. | Automatic adjustment of video orientation |
| US9694351B1 (en) * | 2014-02-26 | 2017-07-04 | Stc.Unm | Highly dispersed and durable heterogeneous catalysts |
| US12303875B2 (en) * | 2015-11-06 | 2025-05-20 | Massachusetts Institute Of Technology | Noble metal monolayer shell coatings on transition metal ceramic nanoparticle cores |
| USD816635S1 (en) * | 2016-03-18 | 2018-05-01 | Bose Corporation | Audio device |
| USD797701S1 (en) * | 2016-03-18 | 2017-09-19 | Bose Corporation | Audio device |
| USD815059S1 (en) | 2016-08-02 | 2018-04-10 | Bose Corporation | Audio device |
| USD821352S1 (en) | 2016-08-02 | 2018-06-26 | Bose Corporation | Audio device |
| USD815058S1 (en) | 2016-08-02 | 2018-04-10 | Bose Corporation | Audio device |
| USD811366S1 (en) | 2016-08-31 | 2018-02-27 | Harman International Industries, Incorporated | Wearable audio component |
| USD851625S1 (en) | 2016-08-31 | 2019-06-18 | Harman International Industries, Incorporated | Wearable audio component |
Family Cites Families (26)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1309636A (en) * | 1969-04-17 | 1973-03-14 | Nat Res Dev | Catalysts |
| US4186110A (en) * | 1978-07-03 | 1980-01-29 | United Technologies Corporation | Noble metal-refractory metal alloys as catalysts and method for making |
| US4192907A (en) * | 1978-07-03 | 1980-03-11 | United Technologies Corporation | Electrochemical cell electrodes incorporating noble metal-base metal alloy catalysts |
| US4316944A (en) * | 1980-06-18 | 1982-02-23 | United Technologies Corporation | Noble metal-chromium alloy catalysts and electrochemical cell |
| US4422917A (en) | 1980-09-10 | 1983-12-27 | Imi Marston Limited | Electrode material, electrode and electrochemical cell |
| US4467050A (en) * | 1982-07-08 | 1984-08-21 | Energy Research Corporation | Fuel cell catalyst member and method of making same |
| US4677092A (en) | 1983-01-17 | 1987-06-30 | International Fuel Cells Corporation | Ordered ternary fuel cell catalysts containing platinum and cobalt and method for making the catalysts |
| US5705265A (en) | 1986-03-24 | 1998-01-06 | Emsci Inc. | Coated substrates useful as catalysts |
| JPS62269751A (en) * | 1986-05-16 | 1987-11-24 | Nippon Engeruharudo Kk | Platinum-copper alloy electrode catalyst and electrode for acidic electrolyte fuel cell using said catalyst |
| US4868841A (en) | 1988-06-13 | 1989-09-19 | Hughes Aircraft Company | Directly heated ceramic catalyst support |
| DE3826503A1 (en) | 1988-08-04 | 1990-02-08 | Kernforschungsanlage Juelich | METAL SHIELDING SYSTEM FOR ELIMINATING HYDROGEN FROM A GAS MIXTURE |
| JPH0697615B2 (en) | 1989-03-09 | 1994-11-30 | エヌ・イーケムキャット株式会社 | Platinum alloy electrode catalyst |
| US5183713A (en) | 1991-01-17 | 1993-02-02 | International Fuel Cells Corporation | Carbon monoxide tolerant platinum-tantalum alloyed catalyst |
| GB9104377D0 (en) | 1991-03-01 | 1991-04-17 | Tseung Alfred C C | Depositing an electrochromic layer |
| US5302258A (en) | 1992-02-28 | 1994-04-12 | Triox Technologies, Inc. | Method and apparatus for separating oxygen from a gaseous mixture |
| DE4221011A1 (en) | 1992-06-26 | 1994-01-05 | Basf Ag | Shell catalysts |
| US5759944A (en) * | 1993-04-20 | 1998-06-02 | Johnson Matthey Public Limited Company | Catalyst material |
| US5597771A (en) | 1993-06-25 | 1997-01-28 | Engelhard Corporation | Layered catalyst composite |
| US5431012A (en) | 1994-07-05 | 1995-07-11 | Ford Motor Company | System for monitoring the performance of automotive catalysts |
| US5680292A (en) | 1994-12-12 | 1997-10-21 | T/J Technologies, Inc. | High surface area nitride, carbide and boride electrodes and methods of fabrication thereof |
| AU4420196A (en) * | 1995-05-01 | 1996-11-21 | E.I. Du Pont De Nemours And Company | Electrochemical cell having an oxide growth resistant curren t distributor |
| KR0166148B1 (en) | 1995-09-05 | 1998-12-15 | 강박광 | Method for preparing a highly dispersed mixed metal oxide supported catalyst |
| US5766789A (en) * | 1995-09-29 | 1998-06-16 | Energetics Systems Corporation | Electrical energy devices |
| DE19611510A1 (en) * | 1996-03-23 | 1997-09-25 | Degussa | Gas diffusion electrode for membrane fuel cells and process for their manufacture |
| US5879827A (en) * | 1997-10-10 | 1999-03-09 | Minnesota Mining And Manufacturing Company | Catalyst for membrane electrode assembly and method of making |
| US5879828A (en) * | 1997-10-10 | 1999-03-09 | Minnesota Mining And Manufacturing Company | Membrane electrode assembly |
-
1999
- 1999-02-22 US US09/253,965 patent/US6297185B1/en not_active Expired - Lifetime
- 1999-02-23 DE DE69927793T patent/DE69927793T2/en not_active Expired - Fee Related
- 1999-02-23 EP EP99907175A patent/EP1060019B1/en not_active Expired - Lifetime
- 1999-02-23 CA CA002321997A patent/CA2321997A1/en not_active Abandoned
- 1999-02-23 WO PCT/US1999/003865 patent/WO1999042213A1/en not_active Ceased
- 1999-02-23 AT AT99907175T patent/ATE306985T1/en not_active IP Right Cessation
- 1999-02-23 AU AU26894/99A patent/AU2689499A/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| EP1060019B1 (en) | 2005-10-19 |
| US6297185B1 (en) | 2001-10-02 |
| EP1060019A1 (en) | 2000-12-20 |
| ATE306985T1 (en) | 2005-11-15 |
| WO1999042213A1 (en) | 1999-08-26 |
| EP1060019A4 (en) | 2002-03-13 |
| DE69927793D1 (en) | 2006-03-02 |
| AU2689499A (en) | 1999-09-06 |
| DE69927793T2 (en) | 2006-07-27 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| EP1060019B1 (en) | Catalyst | |
| US6498121B1 (en) | Platinum-ruthenium-palladium alloys for use as a fuel cell catalyst | |
| JP4541458B2 (en) | Solid polymer fuel cell | |
| KR100431019B1 (en) | Improved composition of a selective oxidation catalyst for use in fuel cells | |
| KR100868756B1 (en) | Pt/Ru alloy supported catalyst, manufacturing method thereof, and fuel cell using the same | |
| EP1164651A1 (en) | Electrode catalyst for polymer electrolyte fuel cell and method for its production | |
| KR20100093525A (en) | Method for producing electrode material for fuel cell, electrode material for fuel cell, and fuel cell using the electrode material for fuel cell | |
| US20060147788A1 (en) | Pt/Ru alloy catalyst for fuel cell | |
| KR20120089858A (en) | Catalyst with metal oxide doping for fuel cells | |
| EP2954579B1 (en) | Co-tolerant catalyst for pafc | |
| JPH07246336A (en) | Anode electrode catalyst for fuel cell and method for producing the same | |
| EP0444138B1 (en) | Electrocatalyst, methods for preparing it, electrodes prepared therefrom and methods for using them | |
| JP7738275B2 (en) | Electrode catalyst layer using electrode catalyst, membrane/electrode assembly and electrochemical device | |
| Lafuente et al. | Single-walled carbon nanotube-supported platinum nanoparticles as fuel cell electrocatalysts | |
| CN112490452B (en) | Fuel cell anode catalyst and preparation method and application thereof | |
| Wan et al. | Novel composite anode with CO “Filter” layers for PEFC | |
| WO2000069009A9 (en) | Platinum-ruthenium-palladium-osmium alloy for use as a fuel cell catalyst |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |