Blended catalyst with improved performance

Abstract

A useful partial oxidation catalyst element includes a catalyst component, a support component, and a substrate. The catalyst component is formed by combining a catalytically active metal with a first support material to form a mixture and calcining the mixture. The support component is formed by calcining a second support material, not containing the active metal. The first and second support materials include particles having an average particle diameter of less than 20 microns. A catalyst material is formed by combining the catalyst component and the support component, wherein the catalyst material contains less than 20% of the catalyst component by weight. The catalyst material is applied to a substrate configured for gas flow therethrough, thereby formulating the partial oxidation catalyst element. The partial oxidation catalyst element is especially useful for fuel reforming and fuel cell applications.