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Attrition Resistant Catalyst Materials for Fluid Bed Applications

Stage: Development
Researchers at NREL have developed novel steam reforming catalyst materials which have improved resistance to loss of catalyst due to attrition when producing hydrogen from gasified biomass. The catalysts prepared can be used for cracking, reforming, water gas shift and gasification reactions on feedstock in a fluidized bed reactor. This technology decreases attrition of the catalyst by fabricating a ceramic support particle, then coating it with an aqueous solution of a precursor salt of a metal, and calcining the coated ceramic to convert the metal salts to metal oxides.


Catalyst support materials of this technology exhibit both attrition resistance and desired support characteristics such as surface area and pore volume. Catalytic activity and selectivity is further enhanced by the addition of varying amounts of metal to the support. The procedure can comprise one or more repetitions of the impregnation of porous solid particles with an aqueous solution of metal salt. The wet solids are then calcined in a furnace with or without a controlled atmosphere. The ceramic support is coated with an aqueous solution of a salt from one of the metals of Ni, Pt, Pd, Ru, Rh, Cr, Co Mn, Mg, K, La, and Fe to fabricate a ceramic support particle that can convert metal salts to metal oxides. The resulting catalyst material is used as a steam reforming catalyst. This may require reduction in the presence of hydrogen first.

For more information, please contact Eric Payne at Eric.Payne@nrel.gov

ROI 03-26

U.S. Patent # 7,915,196


Applications and Industries

The attrition resistant catalysts materials described here can be used to reform gasified biomass, gasified waste grease, gasified plastics mixtures, and volatile compounds from natural gas and petroleum fractions, to produce a hydrogen rich product stream that can be used for producing fuels and chemicals.

Benefits

The use of a fluid bed type reactor has been shown to address the problems of rapid plugging of the interstices between catalyst particles due to solids accumulation seen in fixed bed applications. The solution attempted was to break down pellets to be used in fluidization conditions- but this leads to a new problem of catalyst breakdown by attrition. The present invention solves both of these problems.

Attachments

US Patent 79...6.pdf

Sep 4, 2019