Patent ID: 7037876

Claim:
A method of making a catalyst for the production of hydrogen, said catalyst comprising from about 60 wt % to about 95 wt % Fe 2 O 3 , and from about 0.1 wt % to about 20 wt % chromium in the form of the oxide Cr 2 O 3 , and said method comprising: a) preparing an aqueous organic acid solution, wherein said organic acid is a carboxylic acid having at least one carboxylic acid group with a pK, at ambient temperature of from about 0.5 to about 6; b) adding iron metal to said acid solution; c) forcing an oxidizing agent through said acid solution until said iron metal is consumed and an iron slurry is formed; d) milling said iron slurry to a particle size with a D50 of less than about 2 microns; e) adding at least one promoter to said milled iron slurry to form a product slurry, said promoter being added at a concentration such that said product slurry has a solids content of from about 10% to about 40% inclusive of said promoter; f) drying said slurry to form particles; g) mixing in chromic acid flakes to provide up to about 20 wt % Cr 2 O 3 to the finished catalyst; and g) calcining said particles to form said catalyst.