The present invention provides novel catalysts for accomplishing catalytic
decomposition of undiluted light hydrocarbons to a hydrogen product, and
methods for preparing such catalysts. In one aspect, a method is provided
for preparing a catalyst by admixing an aqueous solution of an iron salt,
at least one additional catalyst metal salt, and a suitable oxide
substrate support, and precipitating metal oxyhydroxides onto the
substrate support. An incipient wetness method, comprising addition of
aqueous solutions of metal salts to a dry oxide substrate support,
extruding the resulting paste to pellet form, and calcining the pellets in
air is also discloses. In yet another aspect, a process is provided for
producing hydrogen from an undiluted light hydrocarbon reactant,
comprising contacting the hydrocarbon reactant with a catalyst as
described above in a reactor, and recovering a substantially carbon
monoxide-free hydrogen product stream. In still yet another aspect, a
process is provided for catalytic decomposition of an undiluted light
hydrocarbon reactant to obtain hydrogen and a valuable multi-walled carbon
nanotube coproduct.
