Disk-type porous Ni–Cr bulk catalyst for hydrogen production by autothermal reforming of methane

Autothermal reforming of methane, which is combined of steam reforming and partial oxidation, was carried out with a disk-type porous Ni–Cr bulk catalyst in various reaction conditions. Although high methane conversion could be obtained by controlling reaction conditions such as reaction temperature, O2/C ratio, and S/C ratio, the optimal condition for maximal H2 and CO generation was shown at a different reaction condition, because H2 and CO were products of partially oxidized methane. The activity of porous Ni–Cr bulk catalyst was well maintained for On–Off test and 260 h operation of ATR. The deactivation of a reforming catalyst has generally been caused by the carbon deposition on the active site of Ni. In the case of bulk Ni, however, the oxidation of Ni was an inevitable and severe problem in the autothermal reforming of methane. An interesting fact was observed during On–Off test, which was named a bounce phenomenon in this work. It was caused by oxidation of Ni for On–Off process and the transient reduction of the oxidized Ni catalyst in ATR reaction.