Catalyst for hydrogen generation through steam reforming of hydrocarbons

1. A catalyst support comprising 95 vol % or more of an alkaline-earth metal hexaaluminate, wherein the catalyst support has a surface area of from 6 m 2 /g to 18 m 2 /g at 950° C.

2. The catalyst support according to claim 1 , wherein the catalyst support comprises 98 vol % or more of the alkaline-earth metal hexaaluminate.

3. The catalyst support according to claim 1 , wherein the catalyst support has a surface area of from 12 m 2 /g to 18m 2 /g at 950° C.

4. The catalyst support according to claim 1 , wherein the alkaline-earth metal hexaaluminate comprises at least one alkaline-earth metal selected from the group consisting of Ca, Sr and Ba.

5. The catalyst support according to claim 1 , wherein the alkaline-earth metal hexaaluminate comprises BaO.6Al 2 O 3 .

6. A method of making a catalyst support, the method comprising

heating at least one precursor oxide in an atmosphere having a partial pressure of O 2 of 0.20 atm or less and containing at least 50 vol % of at least one selected from the group consisting of H 2 , H 2 O and an inert gas; and

producing the catalyst support of claim 1 .

7. The method according to claim 6 , wherein the inert gas is selected from the group consisting of He, Ne, Ar, Kr, Xe and N 2 .

8. The method according to claim 6 , wherein the atmosphere contains at least 50 vol % of N 2 .

9. The method according to claim 6 , wherein the heating is performed at a total pressure of 1 atm.

10. The method according to claim 6 , wherein the heating is performed at a total pressure of less than 1 atm.

11. The method according to claim 6 , wherein the heating is performed at a total pressure of greater than 1 atm.

12. The method according to claim 6 , wherein the precursor oxides are heated in an atmosphere containing a partial pressure of O 2 of 0.10 atm or less.

13. The method according to claim 6 , wherein the heating is at a temperature of no more than 1100° C.

14. The method according to claim 6 , wherein the heating is at a temperature of no more than 950° C.

15. The method according to claim 6 , wherein the heating is at a temperature of no more than 800° C.

16. The method according to claim 6 , wherein the at least one precursor oxide comprises a member of the group consisting of alkaline-earth metal oxides.

17. The method according to claim 6 , the method further comprising heating the at least one precursor oxide in another atmosphere having a partial pressure of O 2 greater than 0.20 atm.

18. The method according to claim 17 , wherein

the other atmosphere is air; and

the total pressure in the other atmosphere is 1 atm.

19. The method according to claim 17 , wherein the heating in the atmosphere having a partial pressure of O 2 of 0.20 atm or less and the heating in the other atmosphere having a partial pressure of O 2 greater than 0.20 atm are each repeated more than once.

20. A catalyst comprising

the catalyst support of claim 1 ; and

an active metal on the catalyst support, wherein

the active metal is selected from the group consisting of Ir, Pt and Pd.

21. The catalyst according to claim 20 , wherein the active metal is dispersed throughout the catalyst support.

22. The catalyst according to claim 20 , wherein the catalyst support comprises 95 vol % or more of barium hexaaluminate; and the active metal comprises Ir.

23. The catalyst according to claim 20 , wherein the catalyst support comprises 95 vol % or more of strontium hexaaluminate; and the active metal comprises Ir.

24. A method of generating H 2 , the method comprising

providing a catalyst comprising

the catalyst support of claim 1 , and

at least one of Ir, Pt and Pd on the catalyst support;

passing over the catalyst an active feedstream comprising a gaseous hydrocarbon and gaseous H 2 O; and

reacting the gaseous hydrocarbon and the gaseous H 2 O in the presence of the catalyst to produce the H 2 .

25. The method according to claim 24 , wherein the active feedstream comprises 10 ppm by mass or more of S.

26. The method according to claim 24 , wherein the active feedstream comprises 100 ppm by mass or more of S.

27. The method according to claim 24 , wherein Ir is on the catalyst support.

28. The method according to claim 24 , wherein the gaseous hydrocarbon comprises at least one selected from the group consisting of methane, ethane, propane and butane.

29. The method according to claim 24 , wherein the active feedstream further comprises 100 ppm by mass or more of O 2 .

30. The method according to claim 29 , wherein the active feedstream comprises 10 ppm by mass or more of S.

31. The method according to claim 29 , wherein the active feedstream comprises 100 ppm by mass or more of S.

32. The method according to claim 29 , wherein Ir is on the catalyst support.

33. The method according to claim 29 , wherein the gaseous hydrocarbon comprises at least one selected from the group consisting of methane, ethane, propane and butane.

34. The method according to claim 24 , further comprising passing over the catalyst an inactive feedstream comprising at least one of air and gaseous H 2 O, wherein the inactive feedstream comprises less than 100 ppm by mass of the gaseous hydrocarbon.

35. The method according to claim 34 , wherein the inactive feedstream comprises 100 ppm by mass or more of O 2 .

36. The method according to claim 34 , wherein the inactive feedstream comprises 1 vol % or more of O 2 .

37. The method according to claim 34 , wherein Ir is on the catalyst support.

38. The method according to claim 34 , wherein each of the active feedstream and the inactive feedstream is passed over the catalyst more than once.

39. The method according to claim 24 , wherein the active feedstream comprises 1 ppm by mass or more of S.