Abstract:
A method for preparing a hydrogen source for a fuel cell by adding an ammonium salt to a slurry of sodium borohydride and a sodium alkoxide in a liquid hydrocarbon.

Description:
[0001]    This application claims the benefit of priority under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 60/962,107 filed on Jul. 26, 2007. 
     
    
     BACKGROUND 
       [0002]    This invention relates generally to a method for preparing a hydrogen source for fuel cells, which comprises ammonium borohydride or ammonium borane, from a slurry of sodium borohydride and a sodium alkoxide in a liquid hydrocarbon. 
         [0003]    Processes for production of ammonium borohydride from liquid sodium borohydride (LSBH) or solid sodium borohydride products are known, but are inefficient in that they use purified sodium borohydride products or non-commercial reaction mixtures as starting materials. For example, U.S. Pat. No. 2,756,259 describes production of ammonium borohydride from a “dry” reaction mixture containing sodium borohydride and a sodium alkoxide. 
         [0004]    The problem addressed by this invention is to provide a more efficient process for producing a hydrogen source for fuel cells using the reaction mixture from a conventional sodium borohydride synthesis. 
       STATEMENT OF INVENTION 
       [0005]    The present invention is directed to a method for producing a hydrogen source for fuel cells from a slurry of sodium borohydride and a sodium alkoxide in a liquid hydrocarbon. The method comprises combining said slurry with 0.99 to 1.01 equivalents of NR 4 (X), and at least one solvent selected from the group consisting of water and methanol; wherein X is halide, hydroxide, alkoxide, acetate or propionate; and each R independently is hydrogen, alkyl, aryl or aralkyl. 
     
    
     DETAILED DESCRIPTION 
       [0006]    Unless otherwise specified, all percentages herein are stated as weight percentages and temperatures are in ° C. 
         [0007]    An “aralkyl” group is an alkyl group substituted by an aryl group, e.g., benzyl, phenylethyl, etc. An “alkyl” group is a saturated hydrocarbyl group having from one to twenty carbon atoms, and may be linear, branched or cyclic. In some embodiments of the invention, alkyl groups are linear or branched, alternatively they are linear. In some embodiments, alkyl groups have from one to ten carbon atoms, alternatively from one to six carbon atoms, alternatively from one to four carbon atoms. An “aryl” group is a substituent derived from an aromatic hydrocarbon compound. An aryl group has a total of from six to twenty ring atoms, and has one or more rings which are separate or fused, and may be substituted by alkyl or halo groups. In some embodiments of the invention, an aryl group is a phenyl or tolyl group. 
         [0008]    Without being bound to theory, it is believed that reaction of sodium borohydride with an unsubstituted ammonium salt produces ammonium borohydride, NH 4 BH 4 , and at temperatures above −40° C., the ammonium borohydride decomposes partially or completely to ammonium borane, NH 3 BH 3  and hydrogen gas. Depending on the temperature of the reaction and the temperature at which the product is maintained, the product may comprise ammonium borohydride, ammonium borane, or a mixture thereof. When substituted ammonium salts are used as starting materials, the substituted ammonium borohydride product is stable. 
         [0009]    Each “R” group in NR 4 BH 4  or NR 4 (X) independently is hydrogen, alkyl, aryl or aralkyl; i.e., there may be a mixture of different alkyl, aryl or aralkyl groups, or the groups may be the same. In some embodiments of the invention, each R independently is hydrogen, C 1 -C 10  alkyl, phenyl, tolyl or benzyl; alternatively hydrogen or C 1 -C 6  alkyl, alternatively hydrogen or C 1 -C 4  alkyl. In some embodiments of the invention, each R is the same group, preferably the same alkyl group. In some embodiments of the invention, each R is hydrogen, i.e., NR 4  is unsubstituted ammonium, NH 4 . 
         [0010]    The liquid hydrocarbon used in the present invention is any hydrocarbon which is liquid at 25° C. Suitable hydrocarbons include alkanes, e.g., mineral oil; and aromatics. Mineral oil is particularly preferred. Preferably, the amount of liquid hydrocarbon in the initial slurry is from 0.01 L/g NaBH 4  to 10 L/g NaBH 4 , alternatively from 0.2 L/g NaBH 4  to 1 L/g NaBH 4 . 
         [0011]    In embodiments of the invention in which X is an alkoxide, the alkoxide is a C 1 -C 12  alkoxide, alternatively a C 1 -C 8  alkoxide, alternatively a C 1 -C 4  alkoxide. In preferred embodiments, the alkoxide is methoxide, ethoxide, isopropoxide or t-butoxide. Methoxide is particularly preferred. In some embodiments of the invention, X is halide, hydroxide, C 1 -C 4  alkoxide, acetate or propionate; alternatively chloride, bromide, iodide, hydroxide, methoxide, ethoxide, acetate or propionate. 
         [0012]    In some embodiments of the invention, the amount of ammonium salt, NR 4 (X) used is from 0.995 to 1.005 equivalents with respect to the amount of sodium borohydride in the slurry, alternatively about one equivalent. In some embodiments of the invention, the sodium alkoxide and sodium borohydride in the slurry are in a molar ratio of about 3:1, alkoxide:borohydride. 
         [0013]    An equation describing the reaction which occurs in a mixed hydrocarbon/water medium, with the sodium alkoxide (present at 3:1 relative to NaBH 4 ) represented as NaOR 1 , is as follows: 
         [0000]      NR 4 (X)+3H 2 O+3NaOR 1 +NaBH 4 →3NaOH+3R 1 OH+NaX+NR 4 BH 4 ( s ) 
         [0000]    NR 4 BH 4  is insoluble in the aqueous/hydrocarbon reaction medium, and thus will form a precipitate. NaX may also be insoluble, depending on the nature of X. In cases where NaX is soluble, the MBH 4  can be isolated by filtration, with the filtrate containing a hydrocarbon phase, and an aqueous alcohol/NaX phase or alcohol/NaX phase, depending on whether water or methanol is added, respectively. If NaX is insoluble, further separation is required to obtain pure NR 4 BH 4 , e.g., by washing with water. 
         [0014]    Preferably, the reaction temperature is from −100° C. to 100° C. In some embodiments, methanol is the solvent, and the temperature is at least −80° C., alternatively at least −70° C., alternatively at least −60° C.; and no greater than −40° C. It is believed that, when each R is hydrogen, ammonium borohydride forms and can remain stable at temperatures no greater than −40° C. If ammonium borohydride is desired as a product, these low temperatures must be maintained. Solid ammonium borohydride will precipitate from methanol, and can be collected by low-temperature filtration. In other embodiments, in which conversion of ammonium borohydride to ammonium borane is not disadvantageous, the reaction temperature is from −10° C. to 100° C. In some embodiments, the reaction temperature is at least 0° C., alternatively at least 10° C., alternatively at least 20° C.; the reaction temperature is no greater than 80° C., alternatively no greater than 70° C., alternatively no greater than 60° C. In embodiments where water is added, preferably, the amount of water added is from 38 g/g NaBH 4  to 68 g/g NaBH 4 , alternatively from 43 g/g NaBH 4  to 53 g/g NaBH 4 . In embodiments where methanol is added, preferably, the amount of methanol added is from 38 g/g NaBH 4  to 68 g/g NaBH 4 , alternatively from 43 g/g NaBH 4  to 53 g/g NaBH 4 . 
         [0015]    The sodium alkoxide in the slurry, NaOR 1 , preferably is a C 1 -C 12  alkoxide, alternatively a C 1 -C 8  alkoxide, alternatively a C 1 -C 4  alkoxide. In preferred embodiments, the alkoxide is methoxide, ethoxide, isopropoxide or t-butoxide. Methoxide is particularly preferred. 
         [0016]    In some embodiments of the invention, NR 4 (X) and methanol and/or water are added together to the slurry. The NR 4 (X) can be dissolved or slurried in the methanol and/or water. Additional methanol and/or water may be added to facilitate handling, if necessary.