Diesel Reforming Over Pyrochlore-Based Monolith

Diesel Reforming over Pyrochlore-Based Monolith

Daniel J. Haynes¹, David A. Berry¹, Dushyant Shekhawat¹, Mark W. Smith², Mathew Seabaugh³, Rich Long³, James J. Spivey ⁴

¹ National Energy Technology Laboratory (NETL), Morgantown, WV 26505

² URS Washington Division, Morgantown, WV 26505

³ NexTech Materials Ltd., Lewis Center, OH 43035

⁴ Louisiana State University, Baton Rouge, LA 70803

NETL has been conducting research in developing a highly active and selective catalyst for the reforming of heavier hydrocarbon feed stocks (i.e. diesel) into a hydrogen-rich synthesis gas.  This is a necessary enabling technology for the commercialization of fuel cells among other applications.  Previously, NETL demonstrated 1000 hrs of continuous diesel reforming using a pyrochlore-based catalyst in powder form.  However it is essential to develop a structured form, which can handle high gaseous throughput with minimal pressure drop.  Key issues in the development of these structured forms include: homogeneity of coating layers, adhesion of catalyst layers (coating stability), thermal stability, and ensuring accessibility of the active sites on the catalytic material.  In this study, a square channel alumina based monolith structure (400 cpi) is first coated with an oxygen-conducting support onto which an active pyrochlore phase was then deposited.  These monoliths were tested for the partial oxidation (POX) and oxidative steam reforming (OSR) of pump diesel fuel.   While no deactivation was observed over the duration of the tests (24h), the catalyst coating layer was not optimized and therefore the lack of homogeneity resulted in insufficient use of active phase.  Imaging of the catalyst shows that there is less than optimum uniformity between the ZDC and the Pyrochlore, and current efforts are directed toward improving the contact between these two components of the catalyst.