Catalytic enhancement of water gas shift reaction with Cu/ZnO/ZSM-5: Overcoming challenges of CO2 and H2 rich feeds

Water gas shift (WGS) reaction commonly converts CO to CO2 using H2O and produces H2 and CO2 in a catalytic fixed bed reactor. This study aims to develop a Cu/ZnO/ZSM-5 catalyst loaded in water gas shift reactor for converting typical synthesis gas produced from dry reforming of methane (DRM) at medium temperature shift (MTS, 200-350 oC) conditions and for preventing reverse reaction due to high feed concentrations of CO2 and H2. The Cu/ZnO/ZSM-5 catalyst was prepared by impregnation method with lower Cu metal loading of 5, 10, and 15 wt%, respectively, compared to commercial catalysts. The synthesized catalyst was characterized using XRF, XRD, SEM, H2-TPR, NH3-TPD, and TGA. The catalyst activity and stability for the WGS reaction were tested in the fixed bed reactor at atmospheric pressure and temperature of 325 degrees C. The experimental results show that CO conversion increases with increasing Cu loading. The 15 wt% Cu/ZnO/ZSM-5 catalyst showed the best results with a CO conversion of 35% and a yield of H2 of 36% and showed good stability for 32 h. Based on the TGA, the 15 wt% Cu/ZnO/ZSM-5 catalyst forms a 0.04 g carbon/g catalyst, which is much lower when compared to commercial catalyst (0.105 g carbon/g catalyst). The relative activity of the synthesized catalyst indicates 2.4 times better when compared to commercial catalysts. High concentrations of H2 and CO2 in the feed may initiate side reactions, including reverse WGS, methanation, and carbon formation, which will decrease H2 yield.