Patent ID: 11926795
Assignee: EXXONMOBIL TECHNOLOGY AND ENGINEERING COMPANY
Field: Chemical engineering (Chemistry)
Classification: CPC C  B  Y | IPC B  C

Claim 16:
17. A method for forming a catalyst system, comprising:
forming a catalyst system comprising a catalyst and a metal oxide support layer that is thermally phase stable at 800° C. to 1600° C., the catalyst having reforming activity and comprising Ni, Rh, Ru, Pd, Pt, Cu, Ir, or a combination thereof, the metal oxide support layer comprising stabilized zirconia, perovskite, pyrochlore, spinel, hibonite, zeolite, an oxide selected from the group consisting of α-Al2O3, LaAlO3, LaAl11O18, MgO, CaO, ZrO2, TiO2, CeO2, Y2O3, La2O3, SiO2, Na2O, K2O, and mixtures thereof, or a combination thereof;
supporting the catalyst system on one or more surfaces of a support structure, the supporting comprising;
depositing an intermediate bonding layer on at least a portion of the one or more surfaces of the support structure, and
supporting at least a portion of the catalyst system on the intermediate bonding layer;

annealing the supported catalyst system and the support structure at an annealing temperature of 1000° C. or more to form an annealed catalyst system and support structure; and
exposing the annealed catalyst system and support structure to cyclic reforming conditions comprising a peak temperature of 1000° C. or more in the presence of a hydrocarbon feed to form H2, the cyclic reforming conditions comprising a reforming step and a regeneration step,
wherein the metal oxide support layer comprises one or more metal oxides, and wherein forming the catalyst system comprises mixing a powder comprising the catalyst with a powder comprising the one or more metal oxides of the metal oxide support layer, the powder comprising the one or more metal oxides of the metal oxide support layer having a surface area of 20 m2/g or less.