A fuel gas-steam reformer assembly, preferably an autothermal reformer assembly,
for use in a fuel cell power plant, includes a catalyst bed which is formed from
a cylindrical monolithic open cell foam body. The foam body is preferably formed
from a high temperature material such as stainless steel, nickel alloys and iron-aluminum
alloys, or from a ceramic material. The foam body includes open cells or pores
which are contained within the metal or ceramic lattice. The lattice is coated
with a porous wash coat which serves as a high surface area substrate onto which
catalysts used in the reformer are applied. The foam body has an inlet end into
which a mixture of fuel, steam and air is fed to begin the reforming process. An
inlet portion of the foam body may be provided with an iron oxide and/or noble
metal catalyst and the remainder of the foam body may be provided with a nickel
and/or noble metal catalyst. An advantage of including an autothermal reformer
in a fuel processing system is the compactness of the autothermal reformer. The
inclusion of the foam catalyst bed rather than the traditional catalyzed pellet
bed allows the reformer to be made even more compact and light weight.