Methanol steam reforming over paper-like composites of Cu/ZnO catalyst and ceramic fiber

Copper–zinc oxide catalyst powders were successfully prepared into paper-like composites, called catalyst paper in this study, using ceramic fibers as the carrier matrix of the catalyst. A papermaking technique with a dual polyelectrolyte retention system was used. Catalyst particles were supported on the ceramic fiber networks tailored in the catalyst paper having various types of pores. Pieces of catalyst paper were subjected to methanol steam reforming (MSR) to produce hydrogen gas for fuel cell applications. They demonstrated a higher performance for methanol conversion and hydrogen production in the MSR reaction than commercial Cu/ZnO catalyst pellets, exhibiting an efficacy equivalent to that of the original catalyst powders. The concentration of carbon monoxide, which acts as a catalytic poison for fuel electrode catalysts, decreased remarkably, without any carbon monoxide reduction system. Moreover, the porous structure of catalyst paper influenced the MSR efficiency. It was assumed that the macropores ca. 20 μm in diameter greatly contributed to the MSR performance, rather than the mesopores on the catalyst surfaces. Thus, the porous, flexible and easy-to-handle catalyst paper is a promising material for practical MSR applications.