Thermally and mechanically stable catalysts for steam reforming and methanation. a new concept in catalyst design

The various catalysts for use in the steam reforming and methanation process produced by existing techniques (such as the impregnation of a relatively high surface area preformed carrier or the forming into pellets of coprecipitated materials) represent a compromise between strength, activity and stability. A process has now been developed to give catalysts which have relatively high catalytic activities but which also have the high mechanical strength of a ceramic matrix. It involves the homogeneous precipitation of precursors of the active component together with promoters and spacers within the pores of a preformed matrix of a low surface area. For example, for use in the steam reforming and methanation processes, the active phase may be derived by calcination and reduction from a coprecipitate consisting of nickel, lanthanum and aluminium species.