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Abstract

A fuel gas-steam reformer assembly, preferably an autothermal reformer assembly, for use in a fuel cell power plant, includes a mixing station for intermixing a relatively high molecular weight fuel and an air-steam stream so as to form a homogeneous fuel-air-steam mixture for admission into a catalyst bed. The catalyst bed includes catalyzed alumina pellets, or a monolith such as a foam or honeycomb body which is preferably formed from a high temperature material such as a steel alloy, or from a ceramic material. The catalyst bed is contained in a shell which is preferably formed from stainless steel or some other high temperature alloy. The shell includes an internal peripheral thermal insulation layer of zirconia (ZrO.sub.2), either in a felt form, or in a rigidified foam. The zirconia insulation layer provides thermal insulation for the shell and retains heat in the catalyst bed and protects the shell against thermal degradation from the hot catalyst bed; and it also protects the catalyst bed against carbon deposition from the fuel and oxygen mixture flowing through the catalyst bed. The use of an internal zirconia insulation layer obviates the need to provide an alumina washcoat and metal oxide coatings on the inner surface of the shell for inhibiting carbon deposition in the catalyst bed. The zirconia insulation layer is non-acidic and possesses carbon gasification properties which are similar to the carbon gasification properties possessed by calcium and alkali metal oxides. Unlike silica insulation, zirconia insulation does not vaporize in the presence of high temperature steam.

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