Preparation of methanol reforming catalysts by Atomic Layer Deposition (ALD)

Abstract

Methanol Steam Reforming (MSR) is of particular interest for fuel cell applications and integrated hydrogen production systems, both as a transportation fuel and for industrial applications, given methanol’s favorable characteristics as a hydrogen carrier. CuO/ZnO/Al₂O₃ (CZA) catalysts for MSR have been widely employed due to their high activity, selectivity, and stability under reaction conditions. This study investigates the synthesis and performance of CZA catalysts for MSR, with a focus on minimizing ZnO content and evaluating Atomic Layer Deposition (ALD) as an alternative to conventional preparation methods. Catalysts with fixed CuO loading and varying ZnO content were prepared by wet impregnation and ALD, and were characterized using XRD, N₂ physisorption, and H₂-TPR. Catalytic activity was assessed in MSR reactions between 250–350 °C. Results revealed that a low ZnO loading (1 wt%) provided favorable textural properties, while the highest methanol conversion was achieved with 10 wt% ZnO. ALD-prepared catalysts demonstrated improved stability and activity at moderate temperatures, along with lower CO selectivity, highlighting the potential of ALD for enhancing catalyst performance.