Paper-structured catalyst with porous fiber-network microstructure for autothermal hydrogen production

Copper-zinc oxide catalyst powders were supported on a microstructured matrix composed of ceramic fiber-network by a papermaking technique. As-prepared catalyst materials, called paper-structured catalyst, were applied to the autothermal reforming (ATR) of methanol to produce hydrogen for fuel cell applications. The paper-structured catalyst demonstrated higher methanol conversion and lower undesirable carbon monoxide concentration, as compared with commercial catalysts. Besides, excellent catalyst durability was exhibited by the suppression of Cu sintering during the ATR reaction. The paper-structured catalyst showed remarkable superiority in methanol conversion even in the case of using sintered catalysts. Such features were possibly induced by the unique fiber-network microstructure (average pore size: ca. 20 μm and porosity: ca. 50%) of the paper composites, which may allow the effective transfer of heat and reactants to the catalyst surfaces. The porous paper-structured catalyst is expected as a promising catalytic material for improving the practical performances in the catalytic gas-reforming process.