Influence of the oxygen pretreatment on the CO2 reforming of methane on Ni/β-SiC catalyst

The influence of the O₂ pretreatment on the CO₂ reforming of methane to synthesis gas has been investigated with Ni catalysts supported on β-SiC extrudate. The structure and properties of the catalysts were characterised by SEM, TEM and XRD techniques. The pretreatment of the catalyst by a mixture of CO₂ and O₂ significantly improves the catalytic activity for the CO₂ reforming. On the Ni 5 wt.% supported on β-SiC catalyst, the CH₄ conversion has reached 90% with the O₂ pretreatment instead of 80% by direct activation under CO₂/CH₄ mixture. The oxygen pretreatment seems to stabilize the metallic nickel phase instead of NiSi₂.     

Structured Ni@NaA zeolite supported on silicon carbide foam catalysts for catalytic carbon dioxide methanation

Carbon dioxide (CO₂) conversion is an important yet challenging topic, which helps to address climate change challenge. Catalytic CO₂ methanation is one of the methods to convert CO₂, however, it is limited by kinetics. This work developed a structured Ni@NaA zeolite supported on silicon carbide (SiC) foam catalyst (i.e., Ni@NaA-SiC), which demonstrated an excellent performance with a CO₂ conversion of ~82%, being comparable to the corresponding equilibrium conversion, and CH₄ selectivity of ~95% at 400°C. The activation energy for CO₂ conversion over the 15Ni@NaA-SiC catalyst is about 31 kJ mol⁻¹, being significantly lower than that of the 15Ni@NaA pelletized catalyst (i.e., ~84 kJ mol⁻¹). Additionally, the structured catalyst was highly stable with sustained CO₂ conversion at 78.7 ± 1.4% and selectivity to CH₄ at 97.7 ± 0.2% over an 80 hr longevity test. In situ diffuse reflectance infrared Fourier transform spectroscopy-mass spectroscopy characterization revealed that catalysis over the structured catalyst proceeded primarily via the CO free mechanism.     

Ni‐Al2O3/Ni‐foam catalyst with enhanced heat transfer for hydrogenation of CO2 to methane

Monolithic Ni‐Al₂O₃/Ni‐foam catalyst is developed by modified wet chemical etching of Ni‐foam, being highly active/selective and stable in strongly exothermic CO₂ methanation process. The as‐prepared catalysts are characterized by x‐ray diffraction scanning electron microscopy, inductively coupled plasma atomic emission spectrometry, and H₂‐temperature programmed reduction‐mass spectrometry. The results indicate that modified wet chemical etching method is working efficiently for one‐step creating and firmly embedding NiO‐Al₂O₃ composite catalyst layer (～2 μm) into the Ni‐foam struts. High CO₂ conversion of 90% and high CH₄ selectivity of >99.9% can be obtained and maintained for a feed of H₂/CO₂ (molar ratio of 4/1) at 320°C and 0.1 MPa with a gas hourly space velocity of 5000 h^?1, throughout entire 1200 h test over 10.2 mL such monolithic catalysts. Computational fluid dynamics calculation and experimental measurement consistently confirm a dramatic reduction of “hotspot” temperature due to enhanced heat transfer. © 2015 American Institute of Chemical Engineers AIChE J, 61: 4323–4331, 2015     

CO2 conversion through combined steam and CO2 reforming of methane reactions over Ni and Co catalysts

Ni‐Co bimetallic and Ni or Co monometallic catalysts prepared for CO₂ reforming of methane were tested with the stimulated biogas containing steam, CO₂, CH₄, H₂, and CO. A mix of the prepared CO₂ reforming catalyst and a commercial steam reforming catalyst was used in hopes of maximizing the CO₂ conversion. Both CO₂ reforming and steam reforming of CH₄ occurred over the prepared Ni‐Co bimetallic and Ni or Co monometallic catalysts when the feed contained steam. However, CO₂ reforming did not occur on the commercial steam reforming catalyst. There was a critical steam content limit above which the catalyst facilitated no more CO₂ conversion but net CO₂ production for steam reforming and water‐gas shift became the dominant reactions in the system. The Ni‐Co bimetallic catalyst can convert more than 70% of CO₂ in a biogas feed that contains ~33 mol% of CH₄, 21.5 mol% of CO₂, 12 mol% of H₂O, 3.5 mol% of H₂, and 30 mol% of N₂. The H₂/CO ratio of the produced syngas was in the range of 1.8‐2. X‐ray absorption spectroscopy of the spent catalysts revealed that the metallic sites of Ni‐Co bimetallic, Ni and Co monometallic catalysts after the steam reforming of methane reaction with equimolar feed (CH₄:H₂O:N₂ = 1:1:1) experienced severe oxidation, which led to the catalytic deactivation.     

Nonthermal plasma (NTP) activated metal–organic frameworks (MOFs) catalyst for catalytic CO2 hydrogenation

A systematic study of Ni supported on metal–organic frameworks (MOFs) catalyst (i.e., 15Ni/UiO-66) for catalytic CO₂ hydrogenation under nonthermal plasma (NTP) conditions was presented. The catalyst outperformed other catalysts based on conventional supports such as ZrO₂, representing highest CO₂ conversion and CH₄ selectivity at about 85 and 99%, respectively. We found that the turnover frequency of the NTP catalysis system (1.8 ± 0.02 s⁻¹) has a nearly two-fold improvement compared with the thermal catalysis (1.0 ± 0.06 s⁻¹). After 20 hr test, XPS and HRTEM characterizations confirmed the stability of the 15Ni/UiO-66 catalyst in the NTP-activated catalysis. The activation barrier for the NTP-activated catalysis was calculated as ~32 kJ mol⁻¹, being lower than the activation energy of the thermal catalysis (~70 kJ mol⁻¹). In situ DRIFTS characterization confirmed the formation of multiple carbonates and formates on catalyst surface activated by NTP, surpassing the control catalysts (e.g., 15Ni/α-Al₂O₃ and 15Ni/ZrO₂).     

Catalytic test of supported Ni catalysts with core/shell structure for dry reforming of methane

Supported nickel catalysts with core/shell structures of Ni/Al₂O₃ and Ni/MgO-Al₂O₃ were synthesized under multi-bubble sonoluminescence (MBSL) conditions and tested for dry reforming of methane (DRM) to produce hydrogen and carbon monoxide. A supported Ni catalyst made of 10% Ni loading on Al₂O₃ and MgO-Al₂O₃, which performed best in the steam reforming of methane (97% methane conversion at 750 °C) and in the partial oxidation of methane (96% methane conversion at 800 °C), showed also good performance in DRM and excellent thermal stability for the first 150 h. The supported Ni catalysts Ni/Al₂O₃ and Ni/MgO-Al₂O₃ yielded methane conversions of 92% and 92.5%, respectively and CO₂ conversions of 95.0% and 91.8%, respectively, at a reaction temperature of 800 °C with a molar ratio of CH₄/CO₂ = 1. Those were near thermodynamic equilibrium values.     

Hydrocarbon steam reforming using Silicalite‐1 zeolite encapsulated Ni‐based catalyst

A Silicalite‐1 zeolite membrane encapsulated 1.6 wt % Ni–1.2 wt % Mg/Ce_0.6Zr_0.4O₂ steam reforming composite catalyst synthesized by a physical coating method was used to investigate effect of encapsulation on size selective steam reforming, using methane (CH₄) and toluene (C₇H₈) as representative species. Characterization methods (scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), Physisorption Analysis, and x‐ray diffraction (XRD)) were used to analyze pre‐ and post‐reaction samples. SEM, EDS, and XRD analyses showed that Silicalite‐1 was coated successfully onto the core catalyst. Weisz‐Prater Criteria and Thiele moduli calculations indicated internal diffusion limitations. Combined reforming of CH₄ and C₇H₈ at 800°C on the composite catalyst demonstrated stability during the 10 h time on stream while the uncoated SR catalyst deactivated. The non‐acidic Silicalite‐1 encapsulated catalyst showed decreases (～2–7%) in both CH₄ and C₇H₈ conversions compared to acidic H‐β zeolite confirming that shell acidity did contribute to conversion and suggested that shell defects/grain boundaries were responsible for the C₇H₈ conversion. © 2016 American Institute of Chemical Engineers AIChE J, 63: 200–207, 2017     

Study on the Anti-Coking Nature of Ni/SrTiO3 Catalysts by the CH4 Pyrolysis

A solid phase crystallization (spc) method was applied for the preparation of SrTiO₃-supported Ni catalysts and compared to the impregnation (imp) method. spc-Ni_0.2/SrTiO₃ has highly dispersed and stable Ni metal particles resulting in higher activity and higher sustainability against coking than imp-Ni_0.2/SrTiO₃ in the partial oxidation of CH₄. Both catalysts were tested for the CH₄ pyrolysis in order to elucidate the catalytic nature against coking of spc-Ni_0.2/SrTiO₃. The amount of carbon and the rate of H₂ formation were similar over both catalysts at both 773 and 1073 K. On both catalysts, CH₄ continuously decomposed at 773 K, while the rate of CH₄ pyrolysis quickly decreased at 1073 K. Fibrous carbons grew up with a Ni metal particle on the tip of the fiber at 773 K, while carbon balls and short carbon fibers with a Ni metal particle encapsulated inside formed and no sufficient growth of the fiber was observed at 1073 K. The carbon species formed at 773 K was hydrogenated completely to CH₄ around 873 K, while the hydrogenation of that formed at 1073 K needed higher temperature around 1073 K. However, the carbon species formed on both the catalysts at either 773 or 1073 K was completely oxidized around 773 K. Thus, judging from the anti-coking nature, the behaviors in the CH₄ pyrolysis are similar over both catalysts, nonetheless spc-Ni_0.2/SrTiO₃ was far superior to imp-Ni_0.2/SrTiO₃ in the CH₄ oxidation. It is likely that the high sustainability against coking of spc-Ni_0.2/SrTiO₃ is not due to its intrinsic nature suppressing the coking but due to its high activity of reforming which can quickly eliminate the carbon formed on the catalyst surface.     

Catalytic Performance of Monolithic Foam Ni/SiC Catalyst in Carbon dioxide Reforming of Methane to Synthesis Gas

Carbon dioxide reforming of methane to synthesis gas has been investigated with Ni catalysts supported on monolithic foam SiC, which were prepared by the initial wetness impregnation method. The catalyst of 7 wt%Ni/SiC was verified to be the best one in different Ni content catalysts. Compared with other catalysts such as 7 wt%Ni/SiO₂ and 7 wt%Ni/Al₂O₃, the 7 wt%Ni/SiC catalyst exhibited not only the highest activity but also remarkable stability and excellent coke resistance during 100 h reaction. Furthermore, the conversion of CO₂ and CH₄ remained at about 96% and 94%, respectively in 100 h reaction time. The structure and properties of the catalysts were characterized by BET, XRD, H₂-TPR, XPS and TEM techniques.     

Determining the Best Composition of a Ni–Fe/Al2O3 Catalyst used for the CO2 Hydrogenation Reaction by Applying Response Surface Methodology

Response surface methodology (RSM) with central composite design (CCD) was applied to determine the composition of an alumina-supported nickel-iron (Ni–Fe) catalyst that provided the highest CH₄ yield for the CO₂ hydrogenation reaction. This involved synthesis of alumina-supported Ni–Fe catalysts of compositions that were specified by CCD. The catalysts were then tested for the CO₂ hydrogenation reaction, and a model equation was developed that related the catalyst composition to the CH₄ yield. The model equation was validated by analysis of variance, and it was found to adequately represent the experimental data. The model equation predicted that the alumina-supported Ni–Fe catalyst containing 32.8% Ni and 7.7% Fe would provide the highest CH₄ yield. A catalyst with this specific composition and the same metal deposition method and two other catalysts of the same composition but different metal deposition metal were also synthesized, characterized, and tested for the CO₂ hydrogenation reaction. The three catalysts did show activities similar to those predicted by the model equation. Furthermore, characterization and reaction studies revealed that the three catalysts were similar, suggesting that the metal deposition methods do not have any effect on the catalytic activity.     

Studies on Carbon Deposition in CO2Reforming of CH4over Nickel–Magnesia Solid Solution Catalysts

Carbon formation behavior under CH₄-CO₂reaction and through CH₄decomposition and CO disproportionation was investigated over Ni_0.03Mg_0.97O solid solution, supported Ni/MgO, and NiO-Al₂O₃catalysts by means of thermogravimetric analysis (TGA) and transmission electron microscopy (TEM). Ni_0.03Mg_0.97O showed high resistance to carbon formation in CO₂reforming of methane and the selectivity to carbon formation was much lower than two other catalysts. It is suggested that CO₂plays an important role in the inhibition of carbon formation on Ni_0.03Mg_0.97O through the activation of CO₂at the interface between small nickel particles and the support surface.     

Suppression of carbon deposition in CO2-reforming of methane on metal sulfide catalysts

The catalytic performance of metal sulfides of Mo and W was studied for the CO₂-reforming of methane by comparing with that of Ni/SiO₂. The sulfide catalysts have lower activity than the Ni/SiO₂ catalyst for this reaction, however, no deactivation due to carbon deposition was observed on the sulfide catalysts. The activity for direct decomposition of CH₄ was much smaller on the sulfides than on supported Ni. The rate equation suggested that, during steady-state reaction, the surface was abundant in adsorbed CO₂ on sulfides, by which direct decomposition of CH₄ should be retarded in addition to their lower activity for this reaction.     

Superior catalytic behavior of trace Pt-doped Ni/Mg(Al)O in methane reforming under daily start-up and shut-down operation

Doping effects of Pt and Ru on Ni/Mg(Al)O catalysts were compared in daily start-up and shut-down operations of steam reforming of CH₄. Trace Pt-doped catalyst showed better behavior than trace Ru-doped catalyst; the former was self-activated but the latter was not, although both exhibited self-regenerative activity. Moreover, the former exhibited sustainable activity, although the latter was quickly passivated, in the autothermal reforming of CH₄. Formation of Pt–Ni alloy on the surface of fine Ni metal particles on the catalysts was suggested by EXAFS analyses. CH₄ was dissociatively activated to form hydrogen on Pt, assisted by adsorbed O or OH species, leading to the self-activation via Ni reduction by hydrogen spillover from Pt. The self-regeneration of the Pt–Ni/Mg(Al)O catalysts can be achieved by the continuous rebirth of active Ni metal species via reversible reduction–oxidation between Ni⁰ and Ni²⁺ in/on Mg(Ni,Al)O periclase assisted by the hydrogen spillover.     

Preferential CO Oxidation in the Presence of H2, H2O and CO2 at Short Contact-times

High selectivities and conversions in the preferential oxidation of CO in the presence of large quantities of H₂, H₂O and CO₂ are demonstrated on noble metal catalysts at millisecond contact times (~10–15 ms) for temperatures between 150 and 500 °C. With a simulated water-gas shift product stream containing 0.5% CO and varying amounts of H₂, H₂O and CO₂, we are able to achieve ~90% CO conversions on a Ru catalyst at temperatures of ~300 °C using a stoichiometric amount of O₂ (0.25%). Experiments with and without O₂ and with varying H₂O reveal that significant water-gas shift occurs on Pt and Pt-ceria catalysts at temperatures between 250 and 400 °C, while significant CH₄ is formed on Ru and Rh catalysts at temperatures greater than 250 and 350 °C, respectively. The presence of H₂O blocks H₂ adsorption and allows preferential CO oxidation at higher temperatures where rates are high. We propose that a multistage preferential oxidation reactor using these catalysts can be used to bring down CO content from 5000 ppm at the reactor entrance to less than 100 ppm at very short contact-times.     

Role of support in CO2 reforming of CH4 over a Ni/γ-Al2O3 catalyst

A catalyst of 10% Ni/γ-Al₂O₃ for CO₂/CH₄ reforming was prepared and characterized by TPR, TPD, XPS, XRD and activity measurements. XPS and TPR showed that Ni mainly exists in the form of NiAl₂O₄ in the calcined catalyst and is hard to reduce below 650°C, indicating a strong interaction between metal and support. Reduction of the calcined catalyst results in fine particles of Ni⁰, with an average diameter of about 20 nm as determined by XRD. The uptake of H on the reduced catalyst measured by H₂-TPD is 4.2–4.6 mole per mole of Ni species and does not depend on the reduction degree of Ni species. This provides a convincing piece of evidence for the occurrence of hydrogen spillover in the reduced catalyst. Only reduced catalysts present good activity, but the degree of nickel reduction has almost no effect on the reforming activity. This seems to suggest that Ni⁰ is vital for the reforming activity, but γ-Al₂O₃ is also involved in CO₂/CH₄ reforming and contributes even more. Based on the mechanism proposed by Bradford et al. and on our observations, a mechanistic model has been proposed to elucidate the role of γ-Al₂O₃ in CO₂/CH₄ reforming.     

Activity of different zeolite-supported Ni catalysts for methane reforming with carbon dioxide

The catalytic performance of Ni based on various types of zeolites (zeolite A, zeolite X, zeolite Y, and ZSM-5) prepared by incipient wetness impregnation has been investigated for the catalytic carbon dioxide reforming of methane into synthesis gas at 700 °C, at atmospheric pressure, and at a CH₄/CO₂ ratio of 1. It was found that Ni/zeolite Y showed better catalytic performance than the other types of studied zeolites. In addition, the stability of the Ni/zeolite Y was greatly superior to that of the other catalysts. A weight of Ni loading at 7 wt.% showed the best catalytic activity on each zeolite support; however, the 7% Ni catalysts produced a higher amount of coke than that of two other Ni loadings, 3 and 5%.     

Ni-Co bimetallic catalyst for CH4 reforming with CO2

A co-precipitation method was employed to prepare Ni/Al₂O₃-ZrO₂, Co/Al₂ O₃-ZrO₂ and Ni-Co/Al₂O₃-ZrO₂ catalysts. Their properties were characterized by N₂ adsorption (BET), thermogravimetric analysis (TGA), temperature-programmed reduction (TPR), temperature-programmed desorption (CO₂-TPD), and temperature-programmed surface reaction (CH₄-TPSR and CO₂-TPSR). Ni-Co/Al₂O₃-ZrO₂ bimetallic catalyst has good performance in the reduction of active components Ni, Co and CO₂ adsorption. Compared with mono-metallic catalyst, bimetallic catalyst could provide more active sites and CO₂ adsorption sites (C + CO₂ = 2CO) for the methane-reforming reaction, and a more appropriate force formed between active components and composite support (SMSI) for the catalytic reaction. According to the CH₄-CO₂-TPSR, there were 80.9% and 81.5% higher CH₄ and CO₂ conversion over Ni-Co/Al₂O₃-ZrO₂ catalyst, and its better resistance to carbon deposition, less than 0.5% of coke after 4 h reaction, was found by TGA. The high activity and excellent anti-coking of the Ni-Co/Al₂O₃-ZrO₂ catalyst were closely related to the synergy between Ni and Co active metal, the strong metal-support interaction and the use of composite support.     

Ni-Co bimetallic catalyst for CH<Subscript>4</Subscript> reforming with CO<Subscript>2</Subscript>

A co-precipitation method was employed to prepare Ni/Al₂O₃-ZrO₂, Co/Al₂ O₃-ZrO₂ and Ni-Co/Al₂O₃-ZrO₂ catalysts. Their properties were characterized by N₂ adsorption (BET), thermogravimetric analysis (TGA), temperature-programmed reduction (TPR), temperature-programmed desorption (CO₂-TPD), and temperature-programmed surface reaction (CH₄-TPSR and CO₂-TPSR). Ni-Co/Al₂O₃-ZrO₂ bimetallic catalyst has good performance in the reduction of active components Ni, Co and CO₂ adsorption. Compared with mono-metallic catalyst, bimetallic catalyst could provide more active sites and CO₂ adsorption sites (C + CO₂ = 2CO) for the methane-reforming reaction, and a more appropriate force formed between active components and composite support (SMSI) for the catalytic reaction. According to the CH₄-CO₂-TPSR, there were 80.9% and 81.5% higher CH₄ and CO₂ conversion over Ni-Co/Al₂O₃-ZrO₂ catalyst, and its better resistance to carbon deposition, less than 0.5% of coke after 4 h reaction, was found by TGA. The high activity and excellent anti-coking of the Ni-Co/Al₂O₃-ZrO₂ catalyst were closely related to the synergy between Ni and Co active metal, the strong metal-support interaction and the use of composite support.     

CO2 reforming and partial oxidation of methane

CO₂ reforming and partial oxidation of CH₄ were investigated on different supported noble metal and Ni catalysts. A detailed thermodynamic analysis was performed for both reactions. The observed reaction behaviour can be predicted by thermodynamics. Product selectivity is catalyst independent, the role of the catalyst is to bring the reactants to approach equilibrium. The partial oxidation is a two-stage process, total oxidation of CH₄ is followed by CO₂ and H₂O reforming of the remaining CH₄. A staged addition of O₂ to the reactor is tested and recommended. TPSR show that the catalyst surface for CO₂ reforming was highly covered with carbonaceous species of four different types; two were identified as reactive intermediates.     

Development of Ni-Pd bimetallic catalysts for the utilization of carbon dioxide and methane by dry reforming

The present research deals with catalyst development for the utilization of CO₂ in dry reforming of methane with the aim of reaching highest yield of the main product synthesis gas (CO, H₂) at lowest possible temperatures. Therefore, Ni-Pd bimetallic supported catalysts were prepared by simple impregnation method using various carriers. The catalytic performance of the catalysts was investigated at 500, 600 and 700 °C under atmospheric pressure and a CH₄ to CO₂ feed ratio of 1. Fresh, spent and regenerated catalysts were characterized by N₂ adsorption for BET surface area determination, XRD, ICP, XPS and TEM. The catalytic activity of the studied Ni-Pd catalysts depends strongly on the support used and decreases in the following ranking: ZrO₂-La₂O₃, La₂O₃ > ZrO₂ > SiO₂ > Al₂O₃ > TiO₂. The bimetallic catalysts were more active than catalysts containing Ni or Pd alone. A Ni to Pd ratio = 4 at a metal loading of 7.5 wt% revealed the best results. Higher loading lead to increased formation of coke; partly in shape of carbon nanotubes (CNT) as identified by TEM. Furthermore, the effect of different calcination temperatures was studied; 600 °C was found to be most favorable. No effect on the catalytic activity was observed if a fresh catalyst was pre-reduced in H₂ prior to use or spent samples were regenerated by air treatment. Ni and Pd metal species are the active components under reaction conditions. Best conversions of CO₂ of 78% and CH₄ of 73% were obtained using a 7.5 wt% NiPd (80:20) ZrO₂-La₂O₃ supported catalyst at a reaction temperature of 700 °C. CO and H₂ yields of 57% and 59%, respectively, were obtained.