Method for improving catalyst function in auto-thermal and partial oxidation reformer-based processors

1. A method for reforming fuel, the method comprising:

a. contacting the fuel to a metallic foam and then an oxidation catalyst so as to partially oxidize the fuel and generate heat wherein the metallic foam preheats the fuel with the generated heat, wherein said oxidation catalyst operates at a first temperature;

b. warming the partially oxidized fuel with the heat while simultaneously warming a reforming catalyst with the heat; and

c. reacting the partially oxidized fuel with steam using the reforming catalyst, wherein the reforming catalyst operates at a second temperature lower than the first temperature wherein the foam and catalysts are contained within a housing, the housing defining an upstream end proximal to an inlet gas preheater region containing the foam and a downstream end, the method further comprising directing the heat from the oxidation catalyst towards said inlet gas preheater region, wherein said inlet gas preheater region is wider in flow through diameter than the downstream end.

2. The method as recited in claim 1 wherein the fuel is a fluid selected from the group consisting of petroleum-derived fuel, bio-derived fuel, synthetic fuel, methane, and combinations thereof.

3. The method as recited in claim 1 wherein the oxidation catalyst and the reforming catalyst are supported on a single contiguous substrate.

4. The method as recited in claim 3 wherein the substrate defines means for facilitating fluid flow throughout the volume of the substrate and from an exterior to an interior of the substrate.

5. The method as recited in claim 3 wherein the substrate is a linear flow structure selected from the group consisting of cordierite, iron chromium aluminum alloy, mullite, alumina, aluminum titanate, and combinations thereof.

6. The method as recited in claim 2 wherein the oxidation catalyst reaches a temperature of at least 850° C. and the reforming catalyst reaches a temperature of no more than 850° C.

7. The method as recited in claim 1 wherein the oxidation catalyst and the reforming catalyst are supported on different substrates.

8. The method as recited in claim 1 further comprising directing the heat in a backwards flow direction from the oxidation catalyst and in a forward flow direction from the oxidation catalyst.

9. The method as recited in claim 1 wherein the method attains a peak temperature and the peak temperature is confined to the oxidation catalyst.

10. The method as recited in claim 1 wherein the method first attains the second temperature in the reforming catalyst and first temperature attained by the method is confined to the oxidation catalyst.

11. The method as recited in claim 3 wherein the method attains the second temperature in the reforming catalyst before the first temperature is confined to the oxidation catalyst.

12. The method as recited in claim 3 wherein the substrate conducts heat from the oxidation catalyst to the reforming catalyst to maintain the temperature of the reforming catalyst above its light off temperature.

13. The method as recited in claim 3 further comprising:

a.) heating the fuel;

b.) using the substrate to transfer heat to the reforming catalyst to cause start up of the method in the reforming catalyst; and

c.) allowing the method to attain peak temperature, whereby the peak temperature moves from the reforming catalyst to the oxidation catalyst.

14. The method as recited in claim 1 wherein the oxidation catalyst has a smaller volume than that of the reforming catalyst.

15. The method as recited in claim 13 wherein all of the oxygen is consumed in the oxidation catalyst after attainment of the peak temperature.

16. The method as recited in claim 1 wherein the oxidation catalyst is selected from the group comprising hexaluminates, spinels, perovskites, garnets, and combinations thereof.

17. The method as recited in claim 1 wherein the oxidation catalyst is selected from the group comprising LaAl 11 O 19 , LaMnAl 11 O 12 , MgAl 2 O 4 , MgMn 0.25 Al 1.75 O 4 , Y 3 Al 5 O 12 , Y 3 Mn 0.1 Al 4.9 O 12 /6Al 2 O 3 , LaMnO 3 , LaCoO 3 , and combinations thereof.

18. The method as recited in claim 1 wherein the reforming catalyst is selected from the group containing Rh, Pt, Pd, Ni, Co, NiO, and combinations thereof.

19. The method as recited in claim 1 wherein the oxidation catalyst and the reforming catalyst are arranged linearly upon a common substrate and wherein the fuel interacts with the oxidation catalyst before the reforming catalyst.