Fuel reformer catalyst

Abstract

A fuel reformer catalyst includes a substrate, and disposed thereon a carrier and combination of at least two metals selected from the group consisting of Rh, Ni, Ir, Pd, Pt, Au, and combinations thereof. Rh is present in the catalyst in an amount not exceeding about 0.5 wt. %, based on the total combined weight of the metals and carrier.

1 . A fuel reformer catalyst comprising a substrate, and disposed thereon a carrier and a combination of at least two metals selected from the group consisting of Rh, Ni, Ir, Pd, Pt, Au, and combinations thereof, wherein the Rh is present in said catalyst in an amount not exceeding about 0.5 wt. %, based on the total combined weight of said metals and said carrier.  
   
   
       2 . The fuel reformer catalyst of  claim 1  comprising a substrate, and disposed thereon a combination of at least two metals selected from the group consisting of Ni, Ir, Pd, Pt, Au, and combinations thereof.  
   
   
       3 . The fuel reformer catalyst of  claim 1  wherein said Ni is present in an amount of about 0.1 wt. % to about 20 wt. %, based on the total weight of said metals and said carrier.  
   
   
       4 . The fuel reformer catalyst of  claim 3  wherein said Ni is present in an amount of about 1 wt. % to about 10 wt. %, based on the total weight of said metals and said carrier.  
   
   
       5 . The fuel reformer catalyst of  claim 4  wherein said Ni is present in an amount of about 5 wt. %, based on the total weight of said metals and said carrier.  
   
   
       6 . The fuel reformer catalyst of  claim 1  wherein said Ir, Pd, Pt, Au, and combinations thereof are each present in an amount of about 0.1 wt. % to about 10 wt. %, based on the total weight of said metals and said carrier.  
   
   
       7 . The fuel reformer catalyst of  claim 6  wherein said Ir, Pd, Pt, Au, and combinations thereof are each present in an amount of about 0.5 wt. % to about 5 wt. %, based on the total weight of said metals and said carrier.  
   
   
       8 . The fuel reformer catalyst of  claim 7  wherein said Ir, Pd, Pt, Au, and combinations thereof are each present in an amount of about 1 wt. % to about 2 wt. %, based on the total weight of said metals and said carrier.  
   
   
       9 . The fuel reformer catalyst of  claim 1  wherein said substrate is selected from the group consisting of spinel, cordierite, zirconia-mullite, titanium aluminate, calcium aluminate, γ-, θ- α-, and δ-alumina, alumina stabilized by La, Ba, Mg, or Ca, zirconium-toughened alumina (ZTA), and combinations thereof.  
   
   
       10 . The fuel reformer catalyst of  claim 9  wherein said substrate is selected from the group consisting of metal-stabilized γ-alumina, zirconia-mullite, zirconium-toughened alumina (ZTA), and combinations thereof.  
   
   
       11 . The fuel reformer catalyst of  claim 1  wherein carrier and said combination of said metals comprise a washcoat, said washcoat being applied to said substrate.  
   
   
       12 . The fuel reformer catalyst of  claim 1  contained within a reactor vessel, said vessel comprising an inlet for fuel and an outlet for product reformate.  
   
   
       13 . The fuel reformer catalyst of  claim 12  comprising a first stage and a second stage, said first stage being disposed proximate said inlet of said vessel, and said second stage being disposed proximate said outlet of said vessel.  
   
   
       14 . The fuel reformer catalyst of  claim 13  wherein said first stage catalyst comprises a metal selected from the group consisting of Ir, Pt, and combinations thereof.  
   
   
       15 . The fuel reformer catalyst of  claim 14  wherein said Ir, Pt, and combinations thereof are each present in an amount of about 0.1 wt. % to about 10 wt. %, based on the total weight of said first stage metals and said carrier.  
   
   
       16 . The fuel reformer catalyst of  claim 15  wherein said Ir is present in an amount of about 10 wt. %, based on the total weight of said first stage metals and said carrier.  
   
   
       17 . The fuel reformer catalyst of  claim 15  wherein said Pt is present in an amount of about 5 wt. %, based on the total weight of said first stage metals and said carrier.  
   
   
       18 . The fuel reformer catalyst of  claim 13  wherein said second stage catalyst comprises a metal selected from the group consisting of Rh, Ni, Ir, Pd, Pt, and combinations thereof, wherein the Rh is present in said second catalyst in an amount not exceeding about 0.5 wt. %, based on the total weight of said second stage metals and said carrier.  
   
   
       19 . The fuel reformer catalyst of  claim 18  wherein said second stage catalyst comprises about 0.5 wt. % Rh.  
   
   
       20 . The fuel reformer catalyst of  claim 18  wherein said second stage catalyst comprises a metal selected from the group consisting of Ni, Ir, Pd, Pt, Au, and combinations thereof.  
   
   
       21 . The fuel reformer catalyst of  claim 18  wherein said second stage catalyst comprises a metal selected from the group consisting of Ni, Ir, Pd, Pt, Au, and combinations thereof.  
   
   
       22 . The fuel reformer catalyst of  claim 21  wherein said Ir, Pd, Pt, Au, and combinations thereof are each present in an amount of about 0.1 wt. % to about 10 wt. %, based on the total weight of said second stage metals and said carrier.  
   
   
       23 . The fuel reformer catalyst of  claim 22  wherein said Ir, Pd, Pt, Au, and combinations thereof are each present in an amount of about 1 wt. % to about 2 wt. %, based on the total weight of said second stage metals and said carrier.  
   
   
       24 . The fuel reformer catalyst of  claim 21  wherein said Ni is present in an amount of about 0.1 wt. % to about 20 wt. %, based on the total weight of said second stage metals and said carrier.  
   
   
       25 . The fuel reformer catalyst of  claim 24  wherein said Ni is present in an amount of about 5 wt. %, based on the total weight of said second stage metals and said carrier.