Reforming Catalysts and Methods of Alcohol Steam Reforming

Abstract

The present invention provides catalysts, reactors, and methods of steam reforming alcohols over a catalyst. Surprisingly superior results and properties obtained in methods and catalysts of the present invention are also described.

1 . (canceled) 
   
   
       2 . A method of alcohol steam reforming comprising passing water and an alcohol in contact with a catalyst under conditions sufficient to obtain a volumetric productivity of at least  10 , 000  ml H 2 /ml catalyst·hr; wherein the catalyst comprises: a metal oxide support; a coating comprising zinc on the metal oxide support; and palladium in contact with said coating. 
   
   
       3 . The method of  claim 2  wherein the alcohol is methanol. 
   
   
       4 . The method of  claim 3  wherein the water and alcohol are contacted with the catalyst at a temperature in the range of 250 to 320° C. 
   
   
       5 - 6 . (canceled) 
   
   
       7 . The method of  claim 2  wherein the metal oxide support constitutes 50 to 90 wt % of the catalyst; zinc oxide constitutes 10 to 30 wt % of the catalyst; and Pd constitutes 1 to 15 wt % of the catalyst. 
   
   
       8 . The method of  claim 7  wherein the metal oxide support comprises alumina, titania or zirconia. 
   
   
       9 . The method of  claim 2 , wherein the water and alcohol are contacted with the catalyst at a temperature in the range of 220 to 350° C., and possessing a volumetric productivity of at least 40,000 ml H 2 /ml catalyst·hr. 
   
   
       10 . The method of  claim 7  possessing a volumetric productivity of 20,000 to 90,000 ml H 2 /ml catalyst·hr. 
   
   
       11 . The method of  claim 7  wherein the catalyst comprises 2 to 10 wt % Pd. 
   
   
       12 . The method of  claim 11  wherein the catalyst comprises 0.2 to 5 wt % Ru. 
   
   
       13 . The method of  claim 2  wherein the metal oxide forms a layer having a thickness less than 1 mm on a large pore support. 
   
   
       14 . The method of  claim 13  wherein the metal oxide forms a layer having a thickness less than 40 μm, and the large pore support comprises a foam or felt. 
   
   
       15 . The method of  claim 14  wherein at least 50% of the catalyst's pore volume is composed of pores in the size range of 0.3 to 200 microns. 
   
   
       16 . The method of  claim 4  wherein the alcohol is at least 80% converted and hydrogen selectivity is at least 60%. 
   
   
       17 . The method of  claim 11  wherein hydrogen selectivity is at least 85%. 
   
   
       18 . The method of  claim 2  wherein the catalyst is disposed in a reaction chamber having a width of less than 2 mm.