Design, scale-up, and operation of a Rh/Ce0.75Zr0.25O2-δ-η-Al2O3/FeCrAl alloy wire mesh honeycomb catalytic module in diesel autothermal reforming

Catalytic autothermal reforming is considered as one of the most effective methods for production of hydrogen from heavy hydrocarbon fuels for solid oxide fuel cells (SOFC). Diesel is an attractive fuel because of its high energy density, widespread use and well - developed infrastructure. Catalysts supported on structured carriers (e.g. FeCrAl modules) provide controlled reaction conditions throughout the reactor volume that favorably compete, for example, with fixed bed reactors. The use of structured catalysts provides efficient heat and mass transfer, low gas dynamic resistance, and high catalyst performance that facilitates the reduction of catalyst quantity per unit volume of the reactor. The ability to perform the process under controlled optimum conditions leads to increased selectivity and minimizes undesirable side reactions, such as coke formation. In the present work, the active component Rh/Ce0.75Zr0.25O2-delta was supported on FeCrAl metal meshes using Al2O3 as a binding structural component. The obtained catalysts Rh/Ce0.75Zr0.25O2-delta-eta-Al2O3/FeCrAl were tested in laboratory and pilot scale reactors in n-hexadecane and diesel autothermal reaction conditions. Winter grade diesel used in the experiments contained up to 31% of aromatics. Operating conditions were found to provide a 100% conversion of n-hexadecane and diesel and stable catalyst activity for a long time-on-stream exposure. The catalysts provided equilibrium product distribution and a maximum syngas (CO + H-2) productivity of 3 m(3)L(cat)(-1)h(-1) (STP) at the studied experimental conditions. The produced syngas can be supplied as a fuel for power generation units based on high-temperature solid oxide fuel cells.