Auto thermal reforming (ATR) catalytic structures

A method for forming a catalytic membrane reactor having an autothermal reforming (ATR) and water-gas-shift (WGS) catalytic layer, the method comprising the steps of:

• introducing a sol-gel to an inner surface of a membrane tube such that the sol-gel contacts the inner surface of the membrane tube, the sol-gel comprising a boehmite solution having a concentration in the range of 5% to 10% aluminum;
• heating the membrane tube to form an inner surface comprising γ-alumina and α-alumina;
• introducing a colloidal sol solution to the inner surface of the membrane tube such that the second sol-gel contacts the membrane tube, the colloidal sol solution comprising an acid, a salt, or combination of both of at least one metal;
• drying the membrane tube such that the acid, salt, or combination of both of the at least one metal is deposited onto the inner surface of the membrane tube;
• calcining the inner surface of the membrane tube such that the at least one metal is calcined;
• and
• reducing the calcined at least one metal under a hydrogen-containing gas such that particles of the at least one metal disperse over pores of the γ-alumina and α-alumina of the inner surface to form the autothermal reforming (ATR) and water-gas-shift (WGS) catalytic layer.