Hydrocarbon reforming catalyst, method of preparing the same and fuel processor including the same

Abstract

A hydrocarbon reforming catalyst, a method of preparing the same, and a fuel processor including the same includes the hydrocarbon reforming catalyst having an active catalyst component impregnated in a oxide carrier and a thermally conductive material having higher thermal conductivity than that of the oxide carrier, the method of preparing the same, and a fuel processor including the same. The hydrocarbon reforming catalyst has excellent catalytic activity and thermal conductivity, and thus can easily transfer heat required in a hydrocarbon reforming reaction. Accordingly, by using the hydrocarbon reforming catalyst above, a high hydrogen production rate can be obtained.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the aspects, taken in conjunction with the accompanying drawings of which:

FIG. 1 is a schematic flowchart illustrating a method of processing fuel in a fuel processor of a related art fuel cell system;

FIG. 2 is a schematic drawing of a structure of a related art hydrocarbon reforming catalyst particle;

FIG. 3 is a schematic drawing of a structure of a hydrocarbon reforming catalyst particle according to an aspect of the present invention;

FIG. 4 is a schematic flowchart illustrating a method of preparing a hydrocarbon reforming catalyst according to an aspect of the present invention;

FIG. 5 is a schematic flowchart illustrating a method of preparing a hydrocarbon reforming catalyst according to another aspect of the present invention;

FIG. 6 is a graph illustrating methane gas conversion according to gas hourly space velocity (GHSV) at 600° C. of a hydrocarbon reforming catalyst of Example 1 and hydrocarbon reforming catalysts of Comparative Examples 1 and 2;

FIG. 7 is a graph illustrating methane gas conversion according to gas hourly space velocity (GHSV) at 600° C. of hydrocarbon reforming catalysts of Examples 2 and 3 and a hydrocarbon reforming catalyst of Comparative Example 3; and

FIG. 8 is a graph illustrating methane gas conversion according to gas hourly space velocity (GHSV) at 700° C. of hydrocarbon reforming catalysts of Examples 2 and 4 and a hydrocarbon reforming catalyst of Comparative Example 1.

Claims

1. A hydrocarbon reforming catalyst, comprising: an active catalyst component impregnated in an oxide carrier; anda thermally conductive material having higher thermal conductivity than that of the oxide carrier.

2. The hydrocarbon reforming catalyst of claim 1, wherein the surface area of the oxide carrier is in the range of 10 to 800 m2/g.

3. The hydrocarbon reforming catalyst of claim 1, wherein the thermal conductivity of the thermally conductive material is in the range of 15 to 600 Wm−1K−1 at room temperature.

4. The hydrocarbon reforming catalyst of claim 1, wherein the oxide carrier comprises at least one of Al2O3, SiO2, TiO2, ZrO2, and CeO2.

5. The hydrocarbon reforming catalyst of claim 1, wherein the thermally conductive material comprises at least one of Al, C, Cu, Co, Fe, Ni, Zn, and Mn.

6. The hydrocarbon reforming catalyst of claim 1, wherein the amount of the oxide carrier is in the range of 10 to 90 wt % of the total weight of the oxide carrier and the thermally conductive material.

7. The hydrocarbon reforming catalyst of claim 1, wherein the amount of the thermally conductive material is in the range of 10 to 90 wt % of the total weight of the oxide carrier and the thermally conductive material.

8. The hydrocarbon reforming catalyst of claim 1, wherein the active catalyst component is formed of at least one of ruthenium (Ru), platinum (Pt), rhodium (Rh), cobalt (Co), nickel (Ni), and palladium (Pd).

9. The hydrocarbon reforming catalyst of claim 1, wherein the amount of the active catalyst component is in the range of 0.1 to 20 wt % of the amount of the hydrocarbon reforming catalyst.

10. A method of preparing a hydrocarbon reforming catalyst, comprising: mixing an oxide carrier and a thermally conductive material having higher thermal conductivity than that of the oxide carrier to form a mixture;impregnating an active catalyst component in the mixture to form a resultant;drying the resultant; andheat treating the dried resultant.

11. The method of claim 10, wherein the average particle size of the thermally conductive material is in the range of 0.1 μm to 5 mm, and the average particle size of the oxide carrier is in the range of 0.1 μm to 5 mm.

12. The method of claim 10, wherein a mixing weight ratio of the thermally conductive material and the oxide carrier is in the range of 1:9 to 9:1.

13. The method of claim 10, wherein the impregnating of the active catalyst component in the mixture is performed using deposition-precipitation, co-precipitation, wet impregnation, sputtering, gas-phase grafting, liquid-phase grafting, or incipient-wetness impregnation.

14. The method of claim 10, wherein the drying of the resultant is performed at 100 to 160° C. for 3 to 5 hours.

15. The method of claim 10, wherein the heat treating of the dried resultant is performed at 500 to 750° C. for 2 to 5 hours.

16. A method of preparing a hydrocarbon reforming catalyst, comprising: impregnating an active catalyst component in an oxide carrier to form a resultant;drying the resultant;mixing the dried resultant with a thermally conductive material having higher thermal conductivity than that of the oxide carrier to form a mixture; andheat treating the mixture.

17. The method of claim 16, wherein the average particle size of the thermally conductive material is in the range of 0.1 μm to 5 mm; and the average particle size of the oxide carrier is in the range of 0.1 μm to 5 mm,

18. The method of claim 16, wherein a mixing weight ratio of the thermally conductive material and the oxide carrier is in the range of 1:9 to 9:1.

19. The method of claim 16, wherein the impregnating of the active catalyst component in the oxide carrier is performed using deposition-precipitation, co-precipitation, wet impregnation, sputtering, gas-phase grafting, liquid-phase grafting, or incipient-wetness impregnation.

20. The method of claim 16, wherein the drying of the resultant is performed at 100 to 160° C. for 3 to 5 hours.

21. The method of claim 16, wherein the heat treating of the mixture is performed at 500 to 750° C. for 3 to 5 hours.

22. A fuel processor, comprising the hydrocarbon reforming catalyst of claim 1.

23. A hydrocarbon reforming catalyst, comprising: an oxide;a catalyst component; anda thermal conductive material having a higher thermal conductivity than that of the oxide, wherein the catalyst component is impregnated into the oxide and/or the thermally conductive material.

24. The hydrocarbon reforming catalyst of claim 23, wherein the oxide comprises at least one of Al2O3, SiO2, TiO2, ZrO2, and CeO2.

25. The hydrocarbon reforming catalyst of claim 23, wherein the thermally conductive material comprises at least one of Al, C, Cu, Co, Fe, Ni, Zn, and Mn.

26. The hydrocarbon reforming catalyst of claim 23, wherein the active catalyst component is of at least one of Ru, Pt, Rh, Co, Ni, and Pd.

27. The hydrocarbon reforming catalyst of claim 23, wherein the catalyst component is impregnated by being interstitially dispersed.

28. A hydrocarbon reforming catalyst, comprising: an oxide;a catalyst component; anda thermal conductive material having a higher thermal conductivity than that of the oxide, wherein the catalyst component is not formed of a shell on the oxide.

29. The hydrocarbon reforming catalyst of claim 28, wherein the oxide comprises at least one of Al2O3, SiO2, TiO2, ZrO2, and CeO2.

30. The hydrocarbon reforming catalyst of claim 28, wherein the thermally conductive material comprises at least one of Al, C, Cu, Co, Fe, Ni, Zn, and Mn.

31. The hydrocarbon reforming catalyst of claim 28, wherein the active catalyst component is of at least one of Ru, Pt, Rh, Co, Ni, and Pd.