This study investigates a strategy to reduce carbon monoxide (CO) content in the product gas from methanol steam reforming, a critical challenge since CO acts as a poison for fuel cell catalysts. To achieve this, bifunctional catalysts were developed on metallic foams. Bifunctional catalysts consisting of a leading layer of reforming catalyst composed of Cu/Zn/Zr oxides, followed by a low temperature water-gas shift (LTS) catalyst layer composed of Cu/Zn oxides, were synthesized over copper and nickel foams that were precoated with a thin layer of Al2O3. The effects of foam material, catalyst loading, share of LTS layer, reactor temperature, feed space velocity and steam to carbon ratio were studied on the performance of the catalyst in a microreactor system regarding methanol conversion, specific hydrogen (H2) production rate and CO content of the product gas. The bifunctionalization approach proved highly effective, achieving over 70 % reduction in CO production, corresponding to a CO content in the product gas of less than 0.4 vol%, accompanied by no significant loss in methanol conversion. The bifunctional catalyst exhibited superior activity at lower temperatures, enhanced long term performance and higher specific H2 production compared to similar studies on mono-functional reforming catalysts. It may be considered as a step forward in portable H2 generator systems via steam reforming of methanol, with a more compact size and less CO production.
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