REFORMING CATALYST FOR MOLTEN CARBONATE FUEL CELLS
The present invention relates to a catalyst composition and a catalyst material which are suitable for use as a reforming catalyst in a fuel cell and are less susceptible to catalyst poisoning by alkali metals. The invention also relates to a catalyst suspension for the preparation of the catalyst composition and the catalyst material, plus a process for the preparation of the catalyst suspension and the catalyst composition. The invention is also directed towards the use of the catalyst composition or the catalyst material in a fuel cell.
1 . Catalyst composition for methane steam reforming, comprising an Ni catalyst and a binding agent, characterized in that the catalyst has a pore volume of at least 200 mm 3 /g.
2 . Catalyst composition according to claim 1 , wherein the pore volume lies between 700 and 800 mm 3 /g.
3 . Catalyst composition according to claim 1 , wherein the catalyst comprises particles having a particle size with a d 50 value of 2 to 10 μm.
4 . Catalyst composition according to claim 3 , wherein the d 50 value lies between 2 and 5 μm.
5 . Catalyst composition according to claim 1 , wherein the catalyst comprises nickel, silicon and aluminium.
6 . Process for the preparation of the catalyst composition for methane steam reforming claim 1 , comprising the steps of
preparing a suspension comprising a binding agent and an Ni catalyst powder in a dispersing medium,
adding a burnout material to the suspension, and
then heating the mixture to produce the catalyst composition.
7 . Process according to claim 6 , wherein an organic polymer, preferably cellulose, comprises the binding agent and a sol comprises the burnout material.
8 . Process according to claim 6 , wherein the process further comprises applying the suspension to a carrier prior to the heating step.
9 . Process according to claim 6 , wherein the heating comprises drying and/or calcining, preferably at 300-400° C.
10 . (canceled)
11 . (canceled)
12 . Process according to claim 6 , wherein the dispersing medium comprises water.
13 . Process according to claim 6 , wherein the suspension is wet-ground before or after the addition of the binding agent.
14 . Process according to claim 6 , wherein the burnout material is added before, after or at the same time as the addition of the binding agent.
15 . Process according to claim 6 , wherein the burnout material comprises an organic material, preferably cellulose.
16 . Process according to claim 6 , wherein 1-30 wt.-%, of burnout material, relative to the dry weight of the suspension, is added.
17 . Process according to claim 6 , wherein the catalyst composition comprises particles having a particle size with a d 50 value of 2 to 10 μm.
18 . Process according to claim 6 , characterized in that the suspension is kept at a pH<7.
19 . Process according to claim 6 , wherein the binding agent comprises a sol, preferably a sol comprising Al 2 O 3 or ZrO 2 nanoparticles.
20 . Catalyst suspension, comprising a catalyst for methane steam reforming and a binding agent, characterized in that the suspension additionally contains a burnout material.
21 . Catalyst suspension according to claim 20 , wherein the suspension contains 1-30 wt.-%, burnout material, relative to the dry weight of the suspension.
22 . Catalyst suspension according to claim 20 , wherein the burnout material comprises an organic material, preferably cellulose.
23 . Catalyst suspension according to claim 20 , characterized in that the binding agent comprises a sol, preferably a sol comprising Al 2 O 3 or ZrO 2 nanoparticles.
24 . (canceled)
25 . Process of claim 6 further comprising burning out the burnout material.
26 . (canceled)
27 . Process according to claim 25 , wherein the calcining is carried out at 250-450° C.
28 . Process according to claim 25 , wherein the catalyst suspension is coated onto a carrier before the burning out.
29 . Process according to claim 28 , wherein the carrier comprises porous material, preferably an Ni foam.
30 . Process according to claim 28 , wherein the carrier has a metal surface.
31 . (canceled)
32 . (canceled)
33 . (canceled)
34 . (canceled)