Reforming catalyst material and processes for making and using same
The present disclosure relates to nickel/aluminum-containing catalyst materials useful, for example, as reforming catalysts, processes for making them, and processes for using them in molten carbonate fuel cells. In one aspect, the disclosure provides a catalyst material including an alumina carrier in an amount in the range of about 5 wt % to about 75 wt %; and a mixed metal oxide in an amount in the range of about 25 wt % to about 95 wt %, the mixed metal oxide including at least about 90 wt % of oxides of nickel and aluminum, the mixed metal oxide having an atomic ratio of nickel to aluminum in the range of about 60:40 to about 90:10, the mixed metal oxide being substantially free of zirconium, in the form of a composite of the alumina carrier and the mixed metal oxide.
1. A catalyst material comprising,
an alumina carrier in an amount in the range of about 25 wt % to about 65 wt %; and
a mixed metal oxide in an amount in the range of about 35 wt % to about 75 wt, the mixed metal oxide including at least about 90 wt % of oxides of nickel and aluminum, the mixed metal oxide having an atomic ratio of nickel to aluminum in the range of about 70:30 to about 90:10, the mixed metal oxide being substantially free of zirconium,
in the form of a fused composite of the alumina carrier and the mixed metal oxide.
2. The catalyst material according to claim 1 , wherein the alumina carrier is substantially γ-alumina.
3. The catalyst material according to claim 1 , wherein the mixed metal oxide includes at least about 95 wt % oxides of nickel and aluminum.
4. The catalyst material according to claim 1 , wherein the mixed metal oxide further includes oxide(s) of one or more additional metals.
5. The catalyst material according to claim 1 , wherein the mixed metal oxide consists essentially of oxides of nickel and aluminum.
6. The catalyst material according to claim 1 , wherein the sum of the amount of the alumina carrier and the mixed metal oxide in the catalyst material is at least about 90%.
7. The catalyst material according to claim 1 , wherein the catalyst material consists essentially of the alumina carrier and the mixed metal oxide.
8. The catalyst material according to claim 1 , wherein the atomic ratio of nickel to aluminum in the mixed metal oxide is about about 75:25 to about 90:10.
9. The catalyst material according to claims 1 , wherein the alumina carrier is present in an amount in the range of about about 45 wt % to about 75wt %, and the mixed metal oxide is present in an amount in the range of about 25wt % to about 55wt %.
10. The catalyst material according to claim 1 , wherein the catalyst material is in the form of a plurality of tablets, pellets or extrudates.
11. The catalyst material according to claim 10 , wherein the plurality of tablets, pellets or extrudates has an average diameter in the range of about 0.7 mm to about 6 mm, and an average pellet length in the range of about 2 mm to about 15 mm.
12. The catalyst material according to claim 1 , wherein the fused composite is a fused composite of particles of the alumina carrier and particles of the mixed metal oxide, and wherein the particles of the alumina carrier have a median particle size in the range of about 0.3 μm to about 1 mm.
13. The catalyst material according to claim 1 , wherein the fused composite is a fused composite of particles of the alumina carrier and particles of the mixed metal oxide, and wherein the particles of the mixed metal oxide have a median particle size in the range of about 0.5 μm to about 2 mm.
14. The catalyst material according to claim 1 , having a pore volume within the range of about 0.1 to about 0.4cm 3 /g.
15. The catalyst material according to claim 1 , having a surface area within the range of from about 100 to about 300 m 2 /g.
16. A process for reforming a hydrocarbon, the process comprising providing a catalyst material according to claim 1 , reducing at least some of the oxide of nickel to metallic nickel to form a reduced catalyst material, and reacting the hydrocarbon with water in the presence of the reduced catalyst material.
17. The process according to claim 16 , performed as a direct internal reforming process in a molten metal carbonate fuel cell.
18. The process according to claim 16 , wherein the reforming is conducted at a temperature in the range of 300 ° C. to 1000 ° C.
19. A fuel cell comprising an anode, a cathode, a metal carbonate electrolyte in contact with the anode and the cathode, and a catalyst material according to claim 1 in fluid communication with the electrolyte.
20. The catalyst material according to claim 1 , wherein the mixed metal oxide includes at least about 98 wt % oxides of nickel and aluminum and wherein the sum of the amount of the alumina carrier and the mixed metal oxide in the catalyst material is at least about 98 %.
21. The catalyst material according to claim 1 , wherein
the alumina carrier is present in an amount in the range of about 25 wt % to about 55 wt %;
the mixed metal oxide is present in an amount in the range of about 45 wt % to about 75 wt %; and
the atomic ratio of nickel to aluminum in the mixed metal oxide is in the range of about 75:25 to about 90:10.
22. The catalyst material according to claim 1 , wherein
the alumina carrier is present in an amount in the range of about 25 wt % to about 55 wt %;
the mixed metal oxide is present in an amount in the range of about 45 wt % to about 75 wt %; and
the atomic ratio of nickel to aluminum in the mixed metal oxide is in the range of about 80:20 to about 90:10.