Attrition resistant fluidizable reforming catalyst

1. A method of preparing a steam reforming catalyst characterized by improved resistance to attrition when used for fluidized bed cracking, water gas shift and gasification reactions on feedstock, said catalyst comprising:

a) less than 10% by weight NiO,

b) less than 5% by weight MgO,

c) less than 10% by weight K 2 O, and

d) a support material comprising at least 90% alpha-alumina;

wherein the support material has a surface area of from 0.1 to 10 m 2 /g, and wherein the catalyst exhibits cracking and reforming activity on biomass derived vapors for at least six hours at 850° C. in a fluidized bed reactor;

said method comprising coating the support material by adding an aqueous solution of precursor salts of Ni, Mg and K to the support material and calcining the coated support material in air to convert the metal salts to metal oxides.

2. The method of claim 1 wherein the aqueous solution further comprises a precursor salt of a metal selected from the group consisting of Pt, Pd, Cu, Ru, Rh, Cr, Co, Mn, La, Fe, and mixtures thereof.

3. The method of claim 1 wherein the aqueous solution of precursor salts comprises Ni(NO 3 ) 2 .6H 2 O.

4. The method of claim 1 wherein the aqueous solution further comprises a precursor salt of Pt.

5. The method of claim 4 wherein the precursor salt is H 2 PtCl 6 .6H 2 O.

6. The method of claim 1 wherein the aqueous solution further comprises a precursor salt of Ru.

7. The method of claim 1 wherein the aqueous solution of precursor salts comprises Mg (NO 3 ) 2 .6 H 2 O.

8. The method of claim 1 wherein the aqueous solution of precursor salts comprises a mixture of Ni, Ru, Mg and K.

9. The method of claim 1 wherein the aqueous solution of precursor salts comprises KNO 3 .

10. The method of claim 1 wherein the aqueous solution of precursor salts comprises a mixture of Ni, Pt, Mg and K.

11. The method of claim 10 wherein the aqueous solution of precursor salts comprises a mixture of Ni(NO 3 ) 2 .6H 2 O, H 2 PtCl 6 .6 H 2 O, Mg (NO 3 ) 2 .6H 2 O and KNO 3 .

12. A steam reforming catalyst having improved resistance to attrition loss when used for cracking, water gas shift and gasification reactions on feedstock in a fluidized bed reactor, said catalyst comprising:

a) less than 10% by weight NiO,

b) less than 5% by weight MgO,

c) less than 10% by weight K 2 O, and

d) a support material comprising at least 90% alpha-alumina;

wherein the support material has a surface area of from 0.1 to 10 m 2 /g, and wherein the catalyst exhibits cracking and reforming activity on biomass derived vapors for at least six hours at 850° C. in a fluidized bed reactor.

13. The steam reforming catalyst of claim 12 , wherein the catalyst exhibits less than 0.5 wt % attrition loss per day in a fluidized bed reactor at 850° C.

14. The steam reforming catalyst of claim 13 , wherein the catalyst further comprises a metal selected from the group consisting of platinum, palladium, iron, ruthenium, rhodium, manganese, copper, cobalt, chromium, lanthanum, a salt of these metals, and mixtures thereof.

15. The steam reforming catalyst of claim 13 , wherein the catalyst further comprises ruthenium or a salt thereof.

16. The steam reforming catalyst of claim 12 , wherein the catalyst further comprises a metal selected from the group consisting of platinum, palladium, iron, ruthenium, rhodium, manganese, copper, cobalt, chromium, lanthanum, a salt of these metals, and mixtures thereof.

17. The steam reforming catalyst of claim 12 , wherein the catalyst further comprises ruthenium or a salt thereof.

18. The steam reforming catalyst of claim 12 , wherein the support material further comprises silica, magnesia or calcia.

19. The steam reforming catalyst of claim 12 , wherein the support material is spherical.

20. The steam reforming catalyst of claim 12 , wherein the size of the support material ranges from 80 μm to 1000 μm.

21. The steam reforming catalyst of claim 12 , wherein the size of the support material ranges from 150 μm to 800 μm.

22. The steam reforming catalyst of claim 12 , wherein the size of the support material ranges from 300 μm to 500 μm.

23. A steam reforming catalyst having improved resistance to attrition loss when used for cracking, water gas shift and gasification reactions on feedstock in a fluidized bed reactor, said catalyst comprising:

a) less than 10% by weight NiO,

b) less than 5% by weight MgO,

c) less than 10% by weight K 2 O, and

d) a support material comprising at least 90% alpha-alumina;

wherein the size of the support material ranges from 80 μm to 1000 μm, and wherein the catalyst exhibits cracking and reforming activity on biomass derived vapors for at least six hours at 850° C. in a fluidized bed reactor.

24. The steam reforming catalyst of claim 23 , wherein the catalyst exhibits less than 0.5 wt % attrition loss per day in a fluidized bed reactor at 850° C.

25. The steam reforming catalyst of claim 24 , wherein the catalyst further comprises ruthenium or a salt thereof.

26. The steam reforming catalyst of claim 23 , wherein the catalyst further comprises a metal selected from the group consisting of platinum, palladium, iron, ruthenium, rhodium, manganese, copper, cobalt, chromium, lanthanum, a salt of these metals, and mixtures thereof.

27. The steam reforming catalyst of claim 23 , wherein the catalyst further comprises ruthenium or a salt thereof.

28. The steam reforming catalyst of claim 23 , wherein the support material further comprises silica, magnesia or calcia.

29. The steam reforming catalyst of claim 23 , wherein the support material is spherical.

30. The steam reforming catalyst of claim 23 , wherein the support material has a surface area of from 0.1 to 10 m 2 /g.