Similarly to the catalysts in primary reformers, the use of high surface secondary reformer catalysts will result in improved activity. The reaction in the secondary reformer is adiabatic and therefore, improved heat transfer is not required. In the past years, the increase in Geometric Surface Area (GSA) has resulted in significant increases in space velocities. The outcome was up to 50% shorter loading catalyst volumes and a bigger area above the catalyst bed in which the combustion can take place (Beyer et al., 2005 p.5). The use of lower catalyst volumes has allowed the construction of smaller secondary reformers and a decrease in pressure drop (Beyer et al., 2005 p.10).

To avoid increase in pressure drop, the secondary reformer catalyst will need to have good thermal stability to withstand the high operating temperatures at the secondary reformer, and improved physical strength (Beyer et al., 2005 p.4).

 Decreasing the catalyste volume in secondary reformer can also provide other benefits. In an Indian plant, the top layer of the catalyst was fused, forming lumps that were difficult to revove, due to poor mixing of process air and proces gas. By reducing the catalyst volume by 14% with the use of more active catalyst, better mixing was obtained and catalyst fusion was avoided (Patel and Mehta, unknown date).