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Materials that are useful for absorption enhanced reforming (AER) of a fuel, including absorbent materials and catalyst materials, and methods for using such materials for the conversion of carbon-based fuels to a H2-rich product gas. The materials can be fabricated by spray processing. The use of t

Materials that are useful for absorption enhanced reforming (AER) of a fuel, including absorbent materials and catalyst materials, and methods for using such materials for the conversion of carbon-based fuels to a H2-rich product gas. The materials can be fabricated by spray processing. The use of the materials in AER can produce a H2 product gas having a high H2 content and a low level of carbon oxides. The method for converting carbon-based fuels to a H2-rich product gas includes forming an intermediate gas product from the carbon-based fuel using a catalyst and contacting the intermediate gas product with an absorbent to absorb CO2. The absorbent can be regenerated while retaining a high absorption capacity.

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What is claimed is: 1. A method for the conversion of a carbon-based fuel to a H2-rich product gas, comprising the steps of: (a) providing a carbon-based fuel selected from a liquid fuel and a gaseous fuel; (b) converting said carbon-based fuel to an intermediate gas product by contacting said carb

What is claimed is: 1. A method for the conversion of a carbon-based fuel to a H2-rich product gas, comprising the steps of: (a) providing a carbon-based fuel selected from a liquid fuel and a gaseous fuel; (b) converting said carbon-based fuel to an intermediate gas product by contacting said carbon-based fuel with at least a first conversion catalyst; (c) contacting said intermediate gas product with an absorbent material to absorb CO2 and form a H2-rich gas, said absorbent material having a theoretical absorption capacity for CO2; (d) extracting said H2-rich gas from said contacting step; (e) regenerating said absorbent; and (f) repeating said steps (a), (b), (c), (d) and (e) at least 50 times, wherein said absorbent material retains at least about 50 mol. % of said theoretical absorption capacity after each of said repeating steps. 2. A method as recited in claim 1, wherein said converting step comprises steam reforming of said carbon-based fuel. 3. A method as recited in claim 1, wherein said converting step is selected from the group consisting of autothermal reforming, partial oxidation and catalytic partial oxidation of said carbon-based fuel. 4. A method as recited in claim 1, further comprising the step of contacting said H2-rich gas with a water-gas shift catalyst. 5. A method as recited in claim 1, wherein said repeating step comprises repeating steps (a), (b), (c),(d) and (e) at least 100 times. 6. A method as recited in claim 1, wherein said repeating step comprises repeating steps (a), (b), (c), (d) and (e) at least 500 times. 7. A method as recited in claim 1, wherein said absorbent material retains at least about 70 mol. % of said theoretical capacity after said repeating step. 8. A method as recited in claim 1, wherein said absorbent material retains at least about 90 mol. % of said theoretical capacity after said repeating step. 9. A method as recited in claim 1, wherein said repeating step comprises repeating steps (a), (b), (c), (d) and (e) at least 200 times and wherein said absorbent material retains at least about 10 mol. % of said theoretical absorption capacity after said repeating step. 10. A method as recited in claim 1, wherein said repeating step comprises repeating steps (a), (b), (c), (d) and (e) at least 200 times and wherein said absorbent material retains at least about 25 mol. % of said theoretical absorption capacity after said repeating step. 11. A method as recited in claim 1, wherein said repeating step comprises repeating steps (a), (b), (c) and (d) at least 200 times and wherein said absorbent material retains at least about 50 mol. % of said theoretical absorption capacity after said repeating step. 12. A method as recited in claim 1, wherein said absorbent material comprises at least one metal oxide selected from the group consisting of Group IA and Group IIA metal oxides. 13. A method as recited in claim 1, wherein said absorbent material comprises a calcium-containing compound. 14. A method as recited in claim 1, wherein said absorbent material comprises CaO. 15. A method as recited in claim 1, wherein said absorbent material comprises CaO:MgO. 16. A method as recited in claim 1, wherein said absorbent material comprises CaO and from about 1 wt. % to about 40 wt. % Al2O3. 17. A method as recited in claim 1, wherein said contacting step occurs at a temperature of not greater than about 800째 C. 18. A method as recited in claim 1, wherein said carbon-based fuel is a hydrocarbon-based fuel. 19. A method as recited in claim 1, wherein said carbon-based fuel is a gaseous fuel. 20. A method as recited in claim 1, wherein said carbon-based fuel comprises methane. 21. A method as recited in claim 1, wherein said carbon-based fuel comprises a liquid fuel. 22. A method as recited in claim 1, wherein said carbon-based fuel comprises a liquid fuel selected from the group consisting of diesel fuel, JP-8 aviation fuel, kerosene, ethanol and gasoline. 23. A method as recited in claim 1, wherein said H2-rich gas comprises at least about 95 mol. % H2 after each said repeating steps. 24. A method as recited in claim 1, wherein said regenerating step comprises heating said absorbent material to a temperature of at least about 700째 C. 25. A method as recited in claim 1, wherein said absorbent material is pelletized. 26. A method as recited in claim 1, wherein said absorbent material is coated on a support structure. 27. A method as recited in claim 1, wherein said absorbent material has substantially spherical morphology. 28. A method for the conversion of a carbon-based fuel to a H2-rich product gas, comprising the steps of: (a) providing a carbon-based fuel selected from a liquid fuel and a gaseous fuel; (b) converting said carbon-based fuel to an intermediate gas product by contacting said carbon-based fuel with at least a first conversion catalyst; (c) contacting said intermediate gas product with an absorbent material having a mass to absorb CO2 and form a H2-rich gas, said absorbent material having an theoretical absorption capacity for CO2; (d) extracting said H2-rich gas from said contacting step; (e) regenerating said absorbent; and (f) repeating said steps (a), (b), (c), (d) and (e) at least 10 times, wherein said mass of absorbent material retains at least about 40 grams CO2 per 100 grams unreacted absorbent after each of said repeating steps. 29. A method as recited in claim 28, wherein said absorbent material retains at least 50 grams CO2 per 100 grams unreacted absorbent after each of said repeating steps. 30. A method as recited in claim 28, wherein said absorbent material is pelletized. 31. A method as recited in claim 28, wherein said converting step comprises steam reforming of said carbon-based fuel. 32. A method as recited in claim 28, wherein said converting step is selected from the group consisting of autothermal reforming, partial oxidation and catalytic partial oxidation of said carbon-based fuel. 33. A method as recited in claim 28, further comprising the step of contacting said H2-rich gas with a water-gas shift catalyst. 34. A method as recited in claim 28, wherein said repeating step comprises repeating steps (a), (b), (c), (d) and (e) at least 50 times. 35. A method as recited in claim 28, wherein said repeating step comprises repeating steps (a), (b), (c), (d) and (e) at least 100 times. 36. A method as recited in claim 28, wherein said repeating step comprises repeating steps (a), (b), (c), (d) and (e) at least 500 times. 37. A method as recited in claim 28, wherein said absorbent retains at least about 70 mol. % of said theoretical absorption capacity after said repeating step. 38. A method as recited in claim 28, wherein said absorbent retains at least about 90 mol. % of said theoretical absorption capacity after said repeating step. 39. A method as recited in claim 28, wherein said repeating step comprises repeating steps (a), (b), (c), (d) and (e) at least 200 times and wherein said absorbent material retains at least about 10 mol. % of said theoretical absorption capacity after said repeating step. 40. A method as recited in claim 28, wherein said repeating step comprises repeating steps (a), (b), (c), (d) and (e) at least 200 times and wherein said absorbent material retains at least about 25 mol. % of said theoretical absorption capacity after said repeating step. 41. A method as recited in claim 28, wherein said repeating step comprises repeating steps (a), (b), (c) and (d) at least 200 times and wherein said absorbent material retains at least about 50 mol. % of said theoretical absorption capacity after said repeating step. 42. A method as recited in claim 28, wherein said absorbent material comprises at least one metal-oxide selected from the group consisting of Group IA and Group IIA metal oxides. 43. A method as recited in claim 28, wherein said absorbent material comprises a calcium-containing compound. 44. A method as recited in claim 28, wherein said absorbent material comprises CaO. 45. A method as recited in claim 28, wherein said absorbent material comprises CaO:MgO. 46. A method as recited in claim 28, wherein said absorbent material comprises CaO and from about 1 wt. % to about 40 wt. % Al2O3. 47. A method as recited in claim 28, wherein said contacting step occurs at a temperature of not greater than about 800째 C. 48. A method as recited in claim 28, wherein said carbon-based fuel is a hydrocarbon-based fuel. 49. A method as recited in claim 28, wherein said carbon-based fuel is a gaseous fuel. 50. A method as recited in claim 28, wherein said carbon-based fuel comprises methane. 51. A method as recited in claim 28, wherein said carbon-based fuel is a liquid fuel. 52. A method as recited in claim 28, wherein said carbon-based fuel comprises a liquid selected from the group consisting of diesel fuel, JP-8 aviation fuel, kerosene, ethanol and gasoline. 53. A method as recited in claim 28, wherein said H2-rich gas comprises at least about 95 mol. % H2 after said repeating step. 54. A method as recited in claim 28, wherein said regenerating step comprises heating said absorbent material to a temperature of at least about 700째 C. 55. A method as recited in claim 28, wherein said absorbent material is pelletized. 56. A method as recited in claim 28, wherein said absorbent material is coated on a support structure. 57. A method as recited in claim 28, wherein said absorbent material has substantially spherical morphology. 58. A method for the conversion of a carbon-based fuel to a H2-rich gas, comprising the steps of: (a) providing a carbon-based fuel selected from a liquid fuel and a gaseous fuel, and steam; (b) converting said carbon-based fuel and said steam to an intermediate gas product by contacting with at least a first conversion catalyst; (c) contacting said intermediate gas product with an absorbent material to absorb CO2 and form an H2-rich gas, said absorbent material having a theoretical absorption capacity and wherein at least said absorbent material is pelletized; (d) extracting said H2-rich gas from said contacting step; (e) regenerating said absorbent; and (f) repeating said steps (a), (b), (c), (d) and (e) at least 50 times, wherein said absorbent material retains at least about 60 mol. % of its theoretical CO2 absorption capacity after each of said repeating steps. 59. A method as recited in claim 58, wherein said absorbent material retains at least about 90 mol. % of said theoretical CO2 absorption capacity after each of said repeating steps. 60. A method as recited in claim 58, wherein said absorbent material retains at least 10 grams CO2 per 100 grams unreacted absorbent material after each of said repeating steps. 61. A method as recited in claim 58, wherein said absorbent material retains at least 20 grams CO2 per 100 grams unreacted absorbent material after each of said repeating steps. 62. A method as recited in claim 58, wherein said absorbent material retains at least 30 grams CO2 per 100 grams unreacted absorbent material after each of said repeating steps. 63. A method as recited in claim 58, wherein said absorbent material retains at least 40 grams CO2 per 100 grams unreacted absorbent material after each of said repeating steps. 64. A method as recited in claim 58, wherein said absorbent material is regenerated at least about 100 times and wherein said absorbent material retains at least about 20 mol. % of said theoretical CO2 absorption capacity. 65. A method as recited in claim 58, wherein said absorbent material has substantially spherical morphology. 66. A method as recited in claim 58, wherein said first conversion catalyst is a steam reforming catalyst. 67. A method as recited in claim 58, further comprising the step of contacting said H2-rich product gas with a water-gas shift catalyst. 68. A method as recited in claim 58, wherein said absorbent material comprises at least one metal oxide selected from the group consisting of Group IA and Group IIA metal oxides. 69. A method as recited in claim 58, wherein said absorbent material comprises a calcium-containing compound. 70. A method as recited in claim 58, wherein said absorbent material comprises CaO. 71. A method as recited in claim 58, wherein said absorbent material comprises CaO and from about 1 wt. % to about 40 wt. % Al2O3. 72. A method as recited in claim 58, wherein said absorbent comprises CaO and a metal oxide selected from the group consisting of Al2O3 and MgO. 73. A method as recited in claim 58, wherein said first conversion catalyst comprises a metal selected from the group consisting of Rh, Ni, Ru, Pt, and Pd. 74. A method as recited in claim 58, wherein said contacting step occurs at a temperature of not greater than about 800째 C. 75. A method as recited in claim 58, wherein said regenerating step comprises heating said absorbent material to a temperature of at least about 700째 C. 76. A method as recited in claim 58, wherein said conversion catalyst is pelletized with said absorbent material. 77. A method as recited in claim 58, wherein said H2-rich product gas comprises at least about 95 mol. % H2.