Methanol steam reforming (MSR) combined with simultaneous hydrogen purification using palladium membranes offers an advanced method for on-board hydrogen utilization in fuel cell vehicles. However, commercial Cu-Zn-Al catalysts typically operate around 300 °C, significantly lower than palladium membranes. In this study, a series of γ-Al2O3 supported and CeO2 and La2O3 modified low-copper catalysts (n%Cu-CL-Al, n% = 2∼6 wt.%) were synthesized and compared with a commercial 45 %Cu-Zn-Al catalyst at 1.1 MPa. The Cu-CL-Al catalysts exhibited higher hydrogen yields (Y [H2]) at temperatures above 400 °C. This performance is attributed to a limited reverse water-gas shift (R-WGS) reaction, facilitated by the strong CO2 absorption properties of rare earth oxides. During long-term stability tests, the activity of the 4 %Cu-CL-Al catalyst significantly decreased after 50 h but rapidly recovered upon oxygen introduction. As no significant carbon deposition was observed on the catalyst surface, and nearly all Cu species in the used catalyst were reduced to Cu0, suggesting that deactivation was due to the over-reduction of Cu species by the generated H2. The presence of O2 accelerated the oxidation rate of Cu0, maintaining an appropriate Cu0/Cu+ ratio for MSR reaction. At 450 °C, Y [H2] was constrained only by the equilibrium of R-WGS reaction, independent of the Cu loading and contact time. This indicates that for on-board hydrogen production using Cu-based catalysts, it is crucial to regulate Cu loading and catalyst quantity to achieve Y [H2] that surpass the equilibrium limit of the chemical reaction.
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