Decomposition of methane in the presence of ethanol over activated carbon catalyst

The interest in hydrogen as a potential fuel of the future has stimulated development of new technologies of its production. The main method of hydrogen production is based on the process of steam reforming of methane, but recently increasing attention has been paid to the catalytic decomposition of methane (CDM) whose advantage is its pro-ecological character. This reaction, besides hydrogen, produces also catalytically low-active carbonaceous deposit which settles on the surface of the catalyst and leads to its deactivation. The study reported is an attempt at suppressing the catalyst deactivation by developing a method leading to formation of carbonaceous deposit potentially active in CDM process. For this purpose, it was proposed that the reaction system would contain methane and ethanol. Simultaneous decomposition of these two substances was performed in parallel at three temperatures of 750, 850 or 950 °C. The catalyst was activated carbon obtained from the hazelnut shells. The addition of ethanol was found to have a positive effect on the course of CDM, leading to an increase in the amount of hydrogen produced and to stabilisation of the catalyst activity at a high level.     

Influence of ethylene on carbon-catalysed decomposition of methane

Catalytic decomposition of methane is a much promising pro-ecological method of hydrogen production. However, the drawback of this method is fast deactivation of the catalyst by deposition of a low-active methane-originated carbon on its surface. In this study an attempt has been made to reduce the process of catalyst deactivation by adding admixture of ethylene to methane directed to the reactor. The study has been performed on the activated carbon obtained by Na₂CO₃ activation of pine wood and two commercial types of activated carbons. All the carbon types have been subjected to ultimate analysis, determination of the surface area and pore structure. It has been shown that ethylene also forms a carbonaceous deposit but in contrast to the methane-originated deposit the ethylene-originated one shows good catalytic properties in the reaction of methane decomposition. The addition of 20% ethylene seems to be optimum for ensuring high yield of hydrogen for a long time. The ethylene admixture addition is the more effective the higher the temperature of the process.     

Catalytic decomposition of methane in the presence of in situ obtained ethylene as a method of hydrogen production

It is predicted that the catalytic decomposition of methane (CDM) can be a promising pro-ecological method of hydrogen production. The main drawback of this process is fast deactivation of the catalyst by the carbonaceous deposit formed on its surface. This problem can be effectively solved e.g. by methane decomposition in the presence of ethylene. However, as ethylene is expensive, an attempt was made to synthesise it in situ, in the process of oxidative coupling of methane (OCM), which was subsequently combined with the CDM process in one reactor. As OCM catalysts the sodium–calcium or lithium–magnesium oxide systems were tested, while the CDM catalyst was activated carbon. The optimum conditions of ethylene production were established and applied to conduct the combined OCM–CDM process. The combined process was found to produce hydrogen in higher yields than when only the activated carbon catalyst was used. This observation was explained by formation of catalytically active carbonaceous deposit appearing as a result of decomposition of ethylene.     

Evolution of the Ni-active centres into ex hydrotalcite oxide catalysts during the COx-free hydrogen production by methane decomposition

The catalytic study of the Ni-catalysts based on Ni/Mg/Al mixed oxides from hydrotalcite-like compounds (ex-LDH) shows a particular behaviour in the methane decomposition reaction. While deactivation of the catalyst occurs in the presence of methane within the range of temperature 600–700 °C, a subsequent and spontaneous “auto-regeneration” of the catalyst is observed above and below this temperature range. Increasing reaction temperature above 700 °C or decreasing it below 600 °C allows recover completely catalytic activity of the deactivated catalyst. This catalyst “auto-regeneration” process is an absolutely reversible process. XPS results of the spent catalysts suggest that the origin of this behaviour is a reversible change in the nature of the carbon deposit as a function of temperature. Consequently, the kinetic control of the carbon formation avoids the catalyst deactivation, and allows to reach the thermodynamic limit of the hydrogen produced.     

Hydrogen production by propylene-assisted decomposition of methane over activated carbon catalysts

Catalytic decomposition of methane (CDM) permits obtaining hydrogen in high yields and – what is essential – it does not lead to release of CO₂. Unfortunately, most of the catalysts used in this process undergo fast deactivation. Their possible regeneration, consisting in the removal of pore blocking carbonaceous deposit of low catalytic activity, leads to generation of undesirable carbon dioxide. An alternative solution for maintaining high catalyst activity in the CDM reaction can be generation of the catalytically active carbonaceous deposit on its surface. Such a deposit can be obtained by decomposition of different organic substances. This paper reports on methane decomposition carried out in the presence of propylene (used in the concentration of 10 or 20%). The reaction was performed at three temperatures of 750 °C, 850 °C or 950 °C. Three types of activated carbon were tested as catalysts: the first one was obtained by activation of pine wood biomass with Na₂CO₃, whereas the second and third ones were commercial carbons (WG-12 and Norit RX3 Extra). According to the results, the addition of propylene to the CDM system effectively reduces deactivation of the activated carbon catalysts and permits fast stabilisation of their catalytic activity at a high level.     

Effect of coexistence of siloxane on production of hydrogen and nanocarbon by methane decomposition using Fe catalyst

Biogas derived from sewage sludge contains CO₂, siloxane, and methane. In this study, the effect of coexistence of siloxane on the production of hydrogen and carbon nanofiber by methane decomposition using iron oxide-alumina catalyst was investigated. The catalyst was reduced by heating in a flow of methane. Siloxane addition to methane caused a catalytic activity at lower temperatures, shortened the induction period prior to the activity, and accelerated catalytic deactivation. Thermal decomposition of siloxane can occur at a lower temperature compared to that of methane. Carbon species formed by the siloxane decomposition may have a higher reducibility than methane does. The reactivity may lead to a carbon deposition at a lower temperature. Coexistence of CO₂ and siloxane can prolong a catalytic lifetime because CO₂ may inhibit the carbon deposition on catalyst to some extent.     

Production of COx-free hydrogen by the thermal decomposition of methane over activated carbon: Catalyst deactivation

Hydrogen, an environment-friendly energy source, is deemed to become strongly in demand over the next decades. In this work, CO_x-free hydrogen was produced by the thermal catalytic decomposition (TCD) of methane by a carbon catalyst. Deactivated catalysts at four-stage of progressive were characterized by nitrogen sorption and scanning electron microscopy. TCD of methane at 820 and 940 °C was about 13- and 8-folds higher than non-catalytic decomposition, respectively. High temperatures positively affected the kinetics of hydrogen production but negatively influenced the total amount of hydrogen and carbon products. The total pore volume was a good indicator of the total amount of hydrogen product. Catalyst activity was decreased because of the changes in the catalyst's textural properties within three ranges of relative time, that is, 0 to 45, 0.45 to 0.65, and 0.65 to 1. Models for specific surface area and total pore volume as functions of catalyst deactivation kinetics were developed.     

Parametric study of the decomposition of methane using a NiCu/Al2O3 catalyst in a fluidized bed reactor

CO₂-free production of hydrogen via catalytic decomposition of methane (CDM) was studied in a fluidized bed reactor (FBR) using a NiCu/Al₂O₃ catalyst. A parametric study of the effects of some process variables, including catalyst particle size, reaction temperature, space velocity and the ratio of gas flow velocity to the minimum fluidization velocity (u_o/u_mf), was undertaken. A mean particle size of 150 μm allows optimization of results in terms of hydrogen production without agglomeration problems. The operating conditions strongly affect the catalyst performance: hydrogen production was enhanced by increasing operating temperature and lowering space velocity. However, increases in operating temperature, space velocity and the ratio u_o/u_mf provoked increases in the catalyst deactivation rate. At 700 °C, carbon was deposited as carbon nanofibers, while higher temperatures promoted the formation of encapsulating carbon, which led to rapid catalyst deactivation.     

Hydrogen production by thermocatalytic decomposition of methane using a fixed bed activated carbon in a pilot scale unit: Apparent kinetic,deactivation and diffusional limitation studies

Thermocatalytic decomposition (TCD) of methane is a promising method to produce hydrogen. A series of experiments was conducted to study the apparent kinetic, catalyst deactivation and effect of mass diffusion for methane TCD to produce hydrogen using palm-shell carbon based activated carbon (ACPS) as a catalyst in a fixed bed reactor. The experiment was carried out under atmospheric pressure at 775–850 °C, and different methane residence times calculated based on changing the ACPS weight at a constant methane flow rate or changing the methane flow rate at a constant ACPS weight. A reaction order as found substantially differs from that found in literature. A deactivation order of 0.5 and deactivation energy of 177 KJ mol⁻¹ is obtained and the results fitted well with a simple developed model. Mass diffusion transfers are accounted for by calculating change of Weisz modulus with time on-stream using different weights of ACPS or different flow rates of methane. The result showed that Weisz modulus decrease with time and it is attributed to the deposition of carbon produced from methane decomposition. Surface properties measurements of the virgin and deactivated ACPSs indicated that methane decomposition occurs mainly within AC micropores.     

Natural sand as a non-conventional catalyst for hydrogen production by methane thermo-catalytic decomposition

The thermo-catalytic decomposition of methane is considered a promising process for H₂ production in the carbon constrained world. A durable and cost-effective catalyst is required for practical methane decomposition processes within industrial applications; unfortunately, most catalysts suffer from extensive deactivation because of carbon deposition. To address this issue, this study assessed a low-cost, widely-available material - natural sand - as a non-conventional catalyst with the realization that it contained impurities such as iron oxides which may impart reaction activity. Its interesting performance in the methane decomposition reaction is reported herein and assessed relative to a potential cause of increasing catalytic activity with longer reaction times. One result of possible significance is the development of tubular carbon structures on the sand's surface that grew significantly in diameter and length with longer reaction times. High Resolution Transmission Electron Microscopy (HRTEM) imaging showed that this tubular carbon contained extensive humps on the external surface of the tube walls which grew in prominence with longer reaction times. The humps did not contain iron particles, in contrast to the heads of the tubes, and consisted of highly disordered graphitic layers. Previous research has pointed to the existence of free radicals or unsaturated bonding in these types of disordered layers, which can provide sites for catalytic reactions. Hence, it is proposed that the increasing prominence of the humps as the reaction time was increased, and by extension an increasing number of surface free radicals, was a possible cause for an increasing catalytic activity after the iron particles on the sand surface were covered with carbon and tube growth was initiated. These data are seen as potentially useful for devising alternative approaches to diminish catalytic deactivation during methane conversion to H₂.     

Chemical looping hydrogen production using activated carbon and carbon black as multi-function carriers

The application of a chemical looping process for methane thermo-catalytic decomposition using activated carbon (AC) as a catalyst has been recognized as an advanced process for continuous high-purity H₂ production in the carbon constrained world due to its low CO₂ formation. AC is able to provide reasonable kinetics, however, it suffers from fast deactivation. Deep regeneration of spent AC catalyst using steam is able to eliminate catalytic deactivation, and this process sacrifices part of the catalyst. The catalytic performance of AC and carbon black (CB) catalysts exhibit opposite deactivation behavior with time. AC provides a better activity, but it deactivates quickly. Though the catalytic activity of CB is low, its activity not only can be maintained, but also shows an increase during the test. Our approach for AC modification was inspired by analyzing the factors that lead to the different performance. Results indicate that the catalytic performance of AC and CB exhibit opposite deactivation behavior with time, and the deposited carbon on their surfaces are in different shape, orientation, and chemical structure. The outward growing cone-like graphene layers and tubular-shaped nanostructures are key factors that help maintain the catalyst's porosity and activity; and the cause of different deposit carbon may be attributed to the irregular, cross-linking graphene layers of AC and the spherical bent graphene layers of CB.     

Hydrogen production by methane decomposition: A comparative study of supported and bulk ex-hydrotalcite mixed oxide catalysts with Ni,Mg and Al

A catalytic comparative study of CO_x-free hydrogen production by methane decomposition was carried out. Catalytic performances of bulk Ni-mixed oxides derived from Ni/Mg/Al-hydrotalcites (ex-HTs-Ni) were compared with those obtained with Ni supported on mixed oxides derived from Mg/Al-hydrotalcites (Ni/ex-HTs), or on commercial supports (γ-Al₂O₃, MgO and MgO-modified γ-Al₂O₃). Catalyst characterization and their catalytic performance showed both ex-HTs-Ni and Ni/ex-HTs appear to be a similar regardless of their method of preparation. Ni/γ-Al₂O₃ was the best supported catalyst, although the catalytic performances of the ex-HTs catalysts were better. Higher NiMg interaction in ex-HTs provides higher resistance to deactivation. Characterization by TG, Raman spectroscopy and TEM of spent catalysts in the reaction suggest the degree of ordering of the graphitic layers of the carbon deposit onto the catalyst surface is the key factor in the catalyst deactivation. The higher degree of ordering or graphitization of the carbon produced with the higher concentration of sp2 carbons on the surface of the Ni/γ-Al₂O₃ favours its faster deactivation by Ni-coverage than the bulk catalyst (ex-HT-Ni), in which the MWNT type carbon is mainly obtained.     

Thermocatalytic decomposition of methane for hydrogen production using activated carbon catalyst: Regeneration and characterization studies

A series of experiments was conducted to study the deactivation and regeneration of activated carbon catalyst used for methane thermocatalytic decomposition to produce hydrogen. The catalyst becomes deactivated due to carbon deposition and six decomposition cycles of methane at temperatures of 850 and 950 °C, and five cycles of regeneration by using CO₂ at temperatures of 900, 950 and 1000 °C were carried out to evaluate the stability of the catalyst. The experiment was conducted by using a thermobalance by monitoring the mass gain during decomposition or the mass lost during the regeneration with time. The initial activity and the ultimate mass gain of the catalyst decreased after each regeneration cycle at both reaction temperatures of 850 and 950 °C, but the amount is smaller under the more severe regenerating conditions. For the reaction at 950 °C, comparison between the first and sixth reaction cycles shows that the initial activity decreased by 69, 51 and 42%, while the ultimate mass gain decreased by 62%, 36% and 16% when CO₂ gasification carried out at 900, 950 and 1000 °C respectively. Temperature -programmed oxidation profiles for the deactivated catalyst at reaction temperature of 950 °C and after several cycles showed two peaks which are attributed to different carbon characteristics, while one peak was obtained when the experiment was carried out at 850 °C. In conclusion, conducting methane decomposition at 950 °C and regeneration at 1000 °C showed the lowest decrease in the mass gain with reaction cycles.     

Metallic and carbonaceous –based catalysts performance in the solar catalytic decomposition of methane for hydrogen and carbon production

Solar catalytic decomposition of methane (SCDM) was investigated in a solar furnace facility with different catalysts. The aim of this exploratory study was to investigate the potential of the catalytic methane decomposition approach providing the reaction heat via solar energy at different experimental conditions. All experiments conducted pointed out to the simultaneous production of a gas phase composed only by hydrogen and un-reacted methane with a solid product deposited into the catalyst particles varying upon the catalysts used: nanostructured carbons either in form of carbon nanofibers (CNF) or multi-walled carbon nanotubes (MWCNT) were obtained with the metallic catalyst whereas amorphous carbon was produced using a carbonaceous catalyst. The use of catalysts in the solar assisted methane decomposition present some advantages as compared to the high temperature non-catalytic solar methane decomposition route, mainly derived from the use of lower temperatures (600–950 °C): SCDM yields higher reaction rates, provides an enhancement in process efficiency, avoids the formation of other hydrocarbons (100% selectivity to H₂) and increases the quality of the carbonaceous product obtained, when compared to the non-catalytic route.     

Ni/Ce-MCM-41 mesostructured catalysts for simultaneous production of hydrogen and nanocarbon via methane decomposition

For the first time, simultaneous production of hydrogen and nanocarbon via catalytic decomposition of methane over Ni-loaded mesoporous Ce-MCM-41 catalysts was investigated. The catalytic performance of the Ni/Ce-MCM-41 catalysts is very stable and the reaction activity remained almost unchanged during 1400 min steam on time at temperatures 540, 560 and 580 °C, respectively. The methane conversion level over these catalysts reached 60–75% with a 100% selectivity towards hydrogen. TEM observations revealed that most of the Ni particles located on the tip of the carbon nanofibers/nanotubes in the used catalysts, keeping their exposed surface clean during the test and thus remaining active for continuous reaction without obvious deactivation. Two kinds of carbon materials, graphitic carbon (C_g) as major and amorphous carbon (C_A) as minor were produced in the reaction, as confirmed by XRD analysis and TEM observations. Carbon nanofibers/nanotubes had an average diameter of approximately 30–50 nm and tens micrometers in length, depending on the reaction temperature, reaction time and Ni particle diameter. Four types of carbon nanofibers/nanotubes were detected and their formations greatly depend on the reaction temperature, time on steam and degree of the interaction between the metallic Ni and support. The respective mechanisms of the formation of nanocarbons were postulated and discussed.     

Influence of space velocity and catalyst pretreatment on COx free hydrogen and carbon nanotubes production over CoMo/MgO catalyst

The influence of catalyst pretreatment and space velocity in methane decomposition into COx-free hydrogen and carbon nanotubes were investigated over CoMo/MgO catalyst. The reduction of catalyst before methane decomposition leads to a hydrogen production without significant formation of COx (concentration lower than 5 ppm after 25 min of reaction) suitable for its use in fuel cells. However, a high hydrogen space velocity in the pretreatment increased the rate of catalyst deactivation. The CO and CO₂ formation rates showed a common trend for all conditions tested: there was a high initial rate and, after 2 min of reaction, there was a lower stabilized rate. The increase in methane space velocity increased the hydrogen formation rate and the degree of carbon nanotubes graphitization. However, it strongly decreases methane conversion, as expected. The use of low hydrogen space velocity, 0.25 h⁻¹, in catalyst pretreatment and high methane space velocity, 8 h⁻¹, in reaction step, provided the highest hydrogen yield and well-structured carbon nanotubes.     

Methane catalytic decomposition over ordered mesoporous carbons: A promising route for hydrogen production

Methane decomposition offers an interesting route for the CO₂-free hydrogen production. The use of carbon catalysts, in addition to lowering the reaction temperature, presents a number of advantages, such as low cost, possibility of operating under autocatalytic conditions and feasibility of using the produced carbons in non-energy applications. In this work, a novel class of carbonaceous materials, having an ordered mesoporous structure (CMK-3 and CMK-5), has been checked as catalysts for methane decomposition, the results obtained being compared to those corresponding to a carbon black sample (CB-bp) and two activated carbons, presenting micro- (AC-mic) and mesoporosity (AC-mes), respectively. Ordered mesoporous carbons, and especially CMK-5, possess a remarkable activity and stability for the hydrogen production through that reaction. Under both temperature programmed and isothermal experiments, CMK-5 has shown to be a superior catalyst for methane decomposition than the AC-mic and CB-bp materials. Likewise, the catalytic activity of CMK-5 is superior to that of AC-mes in spite of the presence of mesoporosity and a high surface area in the latter. The remarkable stability of the CMK-5 catalyst is demonstrated by the high amount of carbon deposits that can be formed on this sample. This result has been assigned to the growth of the carbon deposits from methane decomposition towards the outer part of the catalyst particles, avoiding the blockage of the uniform mesopores present in CMK-5. Thus, up to 25 g of carbon deposits have been formed per gram of CMK-5, while the latter still retains a significant catalytic activity.     

H2 production by methane decomposition: Catalytic and technological aspects

Ni and Co supported on SiO₂ and Al₂O₃ silica cloth thin layer catalysts have been investigated in the catalytic decomposition of natural gas (CDNG) reaction. The influence of carrier nature and reaction temperature was evaluated with the aim to individuate the key factors affecting coke formation. Both Ni and Co silica supported catalysts, due to the low metal support interaction (MSI), promotes the formation of carbon filament with particles at tip. On the contrary, in case alumina was used as support, metals strongly interact with surface thus depressing both the metal sintering and the detachment of particles from catalyst surface. In such cases, carbon grows on metal particle with a “base mechanism” while particles remain well anchored on the catalyst surface. This allowed to realize a cyclic dual-step process based on methane decomposition and catalyst oxygen regeneration without deactivation of catalyst. Technological considerations have led to conclude that the implement of a process based on decomposition and regeneration of catalyst by oxidation requires the development of a robust catalytic system characterized by both a strong MSI and a well defined particle size distribution. In particular, the catalyst should be able to operate at high temperature, necessary to reach high methane conversion values (> 90%), avoiding at the same time the formation of both the carbon filaments with metal at tip or the encapsulating carbon which drastically deactivate the catalyst.     

Unsupported nickel catalyst prepared from nickel foam for methane decomposition and recycling the carbon deposited spent catalyst

Catalytic methane decomposition (CMD) receives increasing attention for co-production of CO_x-free hydrogen and valuable carbon by-product, and the catalyst plays a crucial role on methane conversion and the product features. Unsupported nickel catalysts derived from commercial nickel foam (NF) were prepared for CMD by mild pre-treatment. Effects of the pre-treatment method (acid treatment, thermal treatment, acid-thermal treatment and hydrogen reduction) and reaction temperature were explored on the NF morphology and CMD reactivity in a fixed-bed reactor. It is found that catalytic performance of the NF-based catalyst is highly dependent on the pre-treatment and reaction temperature. The thermal and acid-thermal treatments could greatly promote the catalytic activity (with methane conversion up to 74.6% and 91.8%, respectively) at 850 °C. To fully release potential abilities of the catalyst, the carbon deposited spent catalyst was recycled as a fresh catalyst in the CMD test by several strategies. High and stable methane conversion (up to around 90%–93%) can be achieved by simulating the operation model in a fluidized-bed reactor for a continuous CMD process. Besides, the carbon deposited spent catalyst could serve as a promising candidate of supercapacitor electrode material.