Ni–SiO2 and Ni–Fe–SiO2 catalysts for methane decomposition to prepare hydrogen and carbon filaments

Active and stable Ni–Fe–SiO₂ catalysts prepared by sol–gel method were employed for direct decomposition of undiluted methane to produce hydrogen and carbon filaments at 823 K and 923 K. The results indicated that the lifetime of Ni–Fe–SiO₂ catalysts was much longer than Ni–SiO₂ catalyst at a higher reaction temperature such as 923 K, however, a reverse trend was shown when methane decomposition took place at a lower reaction temperature such as 823 K. XRD studies suggested that iron atoms had entered into the Ni lattice and Ni–Fe alloy was formed in Ni–Fe–SiO₂ catalysts. The structure of the carbon filaments generated over Ni–SiO₂ and Ni–Fe–SiO₂ was quite different. TEM studies showed that “multi-walled” carbon filaments were formed over 75%Ni–25%SiO₂ catalyst, while “bamboo-shaped” carbon filaments generated over 35%Ni–40%Fe–25%SiO₂ catalysts at 923 K. Raman spectra of the generated carbons demonstrated that the graphitic order of the “multi-walled” carbon filaments was lower than that of the “bamboo-shaped” carbon filaments.     

High-performance Ni–SiO2 for pressurized carbon dioxide reforming of methane

The SiO₂ and Ni–SiO₂ were synthesized via the complex-decomposition method by using different organic acids as the complexing agent and fuel. The Ni-supported SiO₂ from different sources was prepared by the incipient impregnation method. The Ni–SiO₂ and Ni/SiO₂ were comparatively evaluated for carbon dioxide reforming of methane (CDR) under severe conditions of CH₄/CO₂ = 1.0, T = 750 °C, GHSV = 53200 mL g⁻¹ h⁻¹, and P = 0.1–1.0 MPa. The materials were fully characterized by XRD, XPS, TEM, TG-DSC, H₂-TPR, and N₂ adsorption-desorption at −196 °C. It was found that the complexing agent and preparation method of the catalyst significantly affected its surface area, the size and dispersion of Ni, the reduction behavior, and the coking and sintering properties, which determine the activity and stability of the catalyst for CDR. As a result, a highly active and stable Ni–SiO₂ for pressurized CDR was obtained by optimizing the complexing agent.     

Production of syngas via autothermal reforming of methane in a fluidized-bed reactor over the combined CeO2–ZrO2/SiO2 supported Ni catalysts

Production of syngas via autothermal reforming of methane (MATR) in a fluidized bed reactor was investigated over a series of combined CeO₂–ZrO₂/SiO₂ supported Ni catalysts. These combined CeO₂–ZrO₂/SiO₂ supports and supported Ni catalysts were characterized by nitrogen adsorption, XRD, NH₃-TPD, CO₂-TPD and H₂-TPR. It was found that the combined supports integrated the advantages of SiO₂ and CeO₂, ZrO₂. That is, they have bigger surface area (about 300 m²/g) than pure CeO₂ and ZrO₂, stronger acidity and alkalescence than that of pure SiO₂, and enhanced the mobility of H adatoms. Ni species dispersed highly on these combined CeO₂–ZrO₂/SiO₂ supports, and became more reducible. Ni catalysts on the combined supports possess higher CO₂ adsorption ability, higher methane activation ability and exhibited higher activity for MATR. H₂/CO ratio in product gas could be controlled successfully in the range of 0.99–2.21 by manipulating the relative concentrations of CO₂ and O₂ in feed.     

Oxidative steam reforming of ethanol over Ni/Al2O3 catalysts promoted by CeO2, ZrO2 and CeO2–ZrO2

Oxidative steam reforming of ethanol at low oxygen to ethanol ratios was investigated over nickel catalysts on Al₂O₃ supports that were either unpromoted or promoted with CeO₂, ZrO₂ and CeO₂–ZrO₂. The promoted catalysts showed greater activity and a higher hydrogen yield than the unpromoted catalyst. The characterization of the Ni-based catalysts promoted with CeO₂ and/or ZrO₂ showed that the variations induced in the Al₂O₃ by the addition of CeO₂ and/or ZrO₂ alter the catalyst's properties by enhancing Ni dispersion and reducing Ni particle size. The promoters, especially CeO₂–ZrO₂, improved catalytic activity by increasing the H₂ yield and the CO₂/CO and the H₂/CO values while decreasing coke formation. This results from the addition of ZrO₂ into CeO₂. This promoter highlights the advantages of oxygen storage capacity and of mobile oxygen vacancies that increase the number of surface oxygen species. The addition of oxygen facilitates the reaction by regenerating the surface oxygenation of the promoters and by oxidizing surface carbon species and carbon-containing products.     

CO2 reforming of CH4 by combination of cold plasma jet and Ni/γ-Al2O3 catalyst

CO₂ reforming of CH₄ to synthesis gas was investigated by cold plasma jet (CPJ) only and combination of cold plasma jet with Ni/γ-Al₂O₃ catalyst at atmospheric pressure. The higher selectivity of H₂ and CO, and higher energy efficiency was obtained by this novel process. The optimum experimental conditions are: CH₄ = 3.33 Nl/min, CO₂ = 5.00 Nl/min, N₂ = 8.33 Nl/min, and the input power at 770 W. The results showed that, for the plasma only, the conversions of CH₄ and CO₂ were 46% and 34%, the selectivities of CO and H₂ were 85% and 78%, the energy efficiency was 2.9 mmol/kJ, respectively; for the combination of cold plasma jet with Ni/γ-Al₂O₃ catalyst, the conversions of CH₄ and CO₂ were increased by 14% and 6%, the yield of H₂ and CO increased by 18% and 11%, the energy efficiency reached at 3.7 mmol/kJ, respectively. And the catalyst hasn't accessorial heating. The CPJ method has the advantage of simple processing and is easy to be industrialized.     

Plasma-reduced Ni/γ–Al2O3 and CeO2–Ni/γ–Al2O3 catalysts for improving dry reforming of propane

Pristine Ni/γ–Al₂O₃ and CeO₂–Ni/γ–Al₂O₃ catalysts were prepared by co-impregnation technique for dry reforming of propane. X-ray diffraction (XRD), field emission scanning electron microscopy (FESEM) and transmission electron microscopy (TEM) were used to examine the structure and morphology of the catalysts before and after the reforming reactions. The excellent interaction between catalyst active phases was observed in both CeO₂–Ni/γ–Al₂O₃ and Ni/γ–Al₂O₃ stabilized with polyethelene glycol (Ni/γ–Al₂O₃–PEG). Towards C₃H₈ and CO₂ conversion, the CeO₂–Ni/γ–Al₂O₃ and Ni/γ–Al₂O₃–PEG showed improved catalytic activity when compared to the pristine Ni/γ–Al₂O₃ catalyst. Interestingly, high H₂ concentration was achieved with the CeO₂–Ni/γ–Al₂O₃ and high CO concentration with the Ni/γ–Al₂O₃–PEG, which is due to the nanoconfinement of nickel particles within the support and favorable metal-support interaction as a result of plasma reduction. The CeO₂–Ni/γ–Al₂O₃ catalyst exhibited better stability for anti-sintering and coke resistance, thus exhibiting high reactivity and durability in the dry reforming.     

Synthesis gas production from CO2 reforming of methane over Ni–Ce/SiO2 catalyst: The effect of calcination ambience

Ni–Ce/SiO₂ catalysts were prepared by calcination under Ar, CO₂, O₂ and H₂ ambience, and applied in CO₂ reforming of methane for synthesis gas production. BET, XRD, XPS, TPR, SEM, TEM and TPH techniques were employed to characterize the fresh and used catalysts. Highly dispersed nickel oxides bearing stronger interaction with SiO₂ prevented the metal sintering. The formation of reactive carbon species on Ni–Ce/SiO₂ catalyst calcined under Ar ambience effectively promoted the carbon elimination and kept the catalyst more stable. Nevertheless, the oxygen storage capacity of CeO₂ might partly lose on Ni–Ce/SiO₂ calcined under H₂ ambience. As a result, the inhibition of carbon elimination and the deposition of inert carbon were responsible for its partial deactivation.     

Methane reforming with carbon dioxide over a Ni/ZiO2–SiO2 catalyst: Influence of pretreatment gas atmospheres

Carbon dioxide reforming of methane to synthesis gas was studied over Ni/ZrO₂–SiO₂ catalyst under different pretreatment atmospheres. Characterization using powder X-ray diffraction, H₂ temperature-programmed reduction, H₂ temperature-programmed hydrogenation, TG/DTA, XPS, Raman spectra and transmission electron microscopy techniques revealed that gas atmospheres employed in the catalyst pretreatment have a significant influence on the catalytic performance. The helium-pretreated catalyst was found to be the most suitable catalyst for this application, showing the improved catalytic performance. More specifically, helium pretreatment facilitated the generation of well-distributed active metal sites while the heterogeneity of Ni components upon H₂ pretreatment degraded catalytic activity of metal sites considerably. Pretreatment under CO atmosphere resulted in the formation of carbon encapsulated metal species thus causing catalyst deactivation severely. Inefficient reduction under CH₄ activation and the presence of a great amount of carbonaceous species, disfavor the production of synthesis gas during the dry reforming.     

Rh promoted and ZrO2/Al2O3 supported Ni/Co based catalysts: High activity for CO2 reforming,steam–CO2 reforming and oxy–CO2 reforming of CH4

Ni (2.5 wt%) and Co (2.5 wt%) supported over ZrO₂/Al₂O₃ were prepared by following a hydrolytic co-precipitation method. The synthesized catalysts were further promoted by Rh incorporation (0.01–1.00 wt%) and tested for their catalytic performance for dry CO₂ reforming, combined steam–CO₂ reforming and oxy–CO₂ reforming of methane for production of syngas. The catalysts were characterized by using N₂ physical adsorption, XRD, H₂–TPR, SEM, CO₂–TPD, NH₃–TPD, TEM and TGA. The results revealed that ZrO₂ phase was in crystalline form in the catalysts along with amorphous Al oxides. Ni and Co were confirmed to be in their respective spinel phases that were reducible to metallic form at 800 °C under H₂. Ni and Co were well dispersed with their nano-crystalline nature. The catalyst with 0.2% loading of Rh showed superior performance in the studied reactions for reforming of methane. This catalyst also showed good coke resistance ability for dry CO₂ reforming reaction with 3.8 wt% of carbon formation during the reaction as compared to 11.6 wt% carbon formation over the catalyst without Rh. The catalyst performance was stable throughout the reaction time for CH₄ conversions, irrespective of carbon formation with slight decline (～1%) in CO₂ conversion. For dry CO₂ reforming reaction, this catalyst showed good conversion for both CH₄ and CO₂ (67.6% and 71.8% respectively) with a H₂/CO ratio of 0.84, while for the Oxy-CO₂ reforming reaction, the activity was superior with CH₄ and CO₂ conversions (73.7% and 83.8% respectively) and H₂/CO ratio of 1.05.     

A study on electrical conductivity of chemosynthetic Al2O3–2SiO2 geoploymer materials

Al₂O₃–2SiO₂ amorphous powders are synthesized by sol–gel method with tetraethoxysilane (TEOS) and aluminum nitrate (ANN) as the starting materials. The microstructure and phase structure of the powders are investigated by SEM and XRD analysis. Geopolymer materials samples are prepared by mechanically mixing stoichiometric amounts of calcined Al₂O₃–2SiO₂ powders and sodium silicate solutions to allow a mass ratio of Na₂O/Al₂O₃ = 0.4, 0.375, 0.35, 0.325, 0.288, 0.26, 0.23 or 0.2 separately, and finally to form a homogenous slurry at a fixed H₂O/Na₂O mole ratio = 11.7. The results show that the synthetic Al₂O₃–2SiO₂ powders have polycondensed property and their compressive strengthes are similar to that of nature metakaolin geopolymer materials. The results also show that the water consumption is not the main influencing factor on electrical conductivity of harden geopolymer materials but it can intensively affect the microstructure of geopolymer materials. In addition, the electrical conductivity of harden geopolymer sample is investigated, and the results show that the geopolymer materials have a high ionic electrical conductivity of about 1.5 × 10⁻⁶ S cm⁻¹ in air at room temperature.     

Characterization and activity test of commercial Ni/Al2O3, Cu/ZnO/Al2O3 and prepared Ni–Cu/Al2O3 catalysts for hydrogen production from methane and methanol fuels

In this study, methane and methanol steam reforming reactions over commercial Ni/Al₂O₃, commercial Cu/ZnO/Al₂O₃ and prepared Ni–Cu/Al₂O₃ catalysts were investigated. Methane and methanol steam reforming reactions catalysts were characterized using various techniques. The results of characterization showed that Cu particles increase the active particle size of Ni (19.3 nm) in Ni–Cu/Al₂O₃ catalyst with respect to the commercial Ni/Al₂O₃ (17.9). On the other hand, Ni improves Cu dispersion in the same catalyst (1.74%) in comparison with commercial Cu/ZnO/Al₂O₃ (0.21%). A comprehensive comparison between these two fuels is established in terms of reaction conditions, fuel conversion, H₂ selectivity, CO₂ and CO selectivity. The prepared catalyst showed low selectivity for CO in both fuels and it was more selective to H₂, with H₂ selectivities of 99% in methane and 89% in methanol reforming reactions. A significant objective is to develop catalysts which can operate at lower temperatures and resist deactivation. Methanol steam reforming is carried out at a much lower temperature than methane steam reforming in prepared and commercial catalyst (275–325 °C). However, methane steam reforming can be carried out at a relatively low temperature on Ni–Cu catalyst (600–650 °C) and at higher temperature in commercial methane reforming catalyst (700–800 °C). Commercial Ni/Al₂O₃ catalyst resulted in high coke formation (28.3% loss in mass) compared to prepared Ni–Cu/Al₂O₃ (8.9%) and commercial Cu/ZnO/Al₂O₃ catalysts (3.5%).     

Methane dry reforming on Ni/Ce0.75Zr0.25O2–MgAl2O4 and Ni/Ce0.75Zr0.25O2–γ-alumina: Effects of support composition and water addition

Nickel catalysts (10wt.%) supported on MgAl₂O₄ and γ-Al₂O₃ were prepared by the wet impregnation method and promoted with various contents of Ce_0.75Zr_0.25O₂. X-ray diffraction (XRD), BET surface area, scanning electron microscopy (SEM), thermal gravimetric analysis (TGA), H₂-temperature programmed reduction (TPR) and CO₂-temperature programmed desorption (TPD) were employed to observe the characteristics of the prepared catalysts. Ni/γ-Al₂O₃ and Ni/Ce_0.75Zr_0.25O₂ (5wt.%)–MgAl₂O₄ showed better activity in CO₂ methane reforming with 75.7(0.93) and 75.4(0.82) CH₄ conversions (and H₂/CO ratio). H₂O was added to feed in the range of H₂O/(CH₄ + CO₂): 0.1–0.5 to suppress reverse water gas shift (RWGS) effect and adjusting H₂/CO ratio. The CH₄ conversions (and H₂/CO) increased to 81(1.1) with 0.5 water/carbon mole ratio in Ni/γ-Al₂O₃ and 85(1.2) with 0.2 water/carbon mole ratio in Ni/Ce_0.75Zr_0.25O₂ (5wt.%)–MgAl₂O₄. The stability of Ni/Ce_0.75Zr_0.25O₂ (5wt.%)–MgAl₂O₄ in the presence and absence of water was investigated. Coke formation and amount in used catalysts were examined by SEM and TGA, respectively. The results showed that the amount of carbon was suppressed and negligible coke formation (less than 3%) was observed in the presence of 0.2 water/carbon mole ratio over Ni/Ce_0.75Zr_0.25O₂ (5wt.%)–MgAl₂O₄ catalyst.     

H2 and CO production over a stable Ni–MgO–Ce0.8Zr0.2O2 catalyst from CO2 reforming of CH4

Ni–Ce_0.8Zr_0.2O₂ and Ni–MgO–Ce_0.8Zr_0.2O₂ catalysts were investigated for H₂ production from CO₂ reforming of CH₄ reaction at a very high gas hourly space velocity of 480,000 h⁻¹. Ni–MgO–Ce_0.8Zr_0.2O₂ exhibited higher catalytic activity and stability (CH₄ conversion >95% at 800 °C for 200 h). The outstanding catalytic performance is mainly due to the basic nature of MgO and an intimate interaction between Ni and MgO.     

The graphene-meso-macroporous SiO2 supported Pt–Ni alloy nanocatalyst for preferential oxidation of CO in H2-rich gases

In this work, nanoparticles of Pt–Ni alloy were supported on a new kind of composite which composed of graphene sheets and meso-macroporous SiO₂, and the composite supported Pt–Ni catalyst was applied to the preferential oxidation of CO (CO-PROX) in H₂-rich gases. The bimetallic Pt–Ni alloy catalyst was characterized by using techniques of SEM, TEM, XRD, TPR, CO chemisorptions and XPS. The catalyst showed excellent catalytic performance for CO-PROX with high activity at low temperature, high selectivity and very good stability, which was attributed to the following characters of the catalyst: Pt–Ni nanoparticles were in alloy state and highly dispersed, Pt–Ni nanoparticles were preferentially loaded on the surface of graphene sheets, and the meso-macroporosity of the composite markedly improved the mass transferring ability. This is a case study, and this kind of catalysts can be extended to other gas–solid catalytic reactions.     

Synthesis and characterization of bimetallic Cu–Ni/ZrO2 nanocatalysts: H2 production by oxidative steam reforming of methanol

Cu/ZrO₂, Ni/ZrO₂ and bimetallic Cu–Ni/ZrO₂ catalysts were prepared by deposition–precipitation method to produce hydrogen by oxidative steam reforming of methanol (OSRM) reaction in the range of 250–360 °C. TPR analysis of the Cu–Ni/ZrO₂ catalyst showed that the presence of Cu facilitates the reduction of the Ni at lower temperatures. In addition, this sample showed two reduction peaks, the former peak was attributed to the reduction of the adjacent Cu and Ni atoms which could be forming a bimetallic Cu-rich phase, and the second was assigned to the remaining Ni atoms forming bimetallic Ni-rich nanoparticles. Transmission Electron Microscopy revealed Cu or Ni nanoparticles on the monometallic samples, while bimetallic nanoparticles were identified on the Cu–Ni/ZrO₂ catalyst. On the other hand, Cu–Ni/ZrO₂ catalyst exhibited better catalytic activity than the monometallic samples. The difference between them was related to the Cu–Ni nanoparticles present on the former catalyst, as well as the bifunctional role of the bimetallic phase and the support that improve the catalytic activity. All the catalysts showed the same selectivity toward H₂ at the maximum reaction temperature and it was ∼60%. The high selectivity toward CO is associated to the presence of the bimetallic Ni-rich nanoparticles, as evidenced by TEM–EDX analysis, since this behavior is similar to the one showed by the monometallic Ni-catalyst.     

Catalytic performance of Pd–NiCo2O4/SiO2 in lean methane combustion at low temperature

In this paper, the catalyst of Pd–NiCo₂O₄/SiO₂ was prepared and applied to the catalytic combustion of lean methane. Pd and NiCo₂O₄ nanoparticles were uniformly distributed on the SiO₂ support, so that every Pd or NiCo₂O₄ nanoparticle was separated from each other by another component. Comparing with Co₃O₄/SiO₂, NiCo₂O₄/SiO₂, Pd–Co₃O₄/SiO₂ and Pd#NiCo₂O₄/SiO₂ (catalysts without uniform distribution of Pd and NiCo₂O₄ nanoparticles), Pd–NiCo₂O₄/SiO₂ had the highest catalytic activity in the catalytic combustion of lean methane, with a methane total conversion temperature at 378 °C. In addition, the high activity did not decrease during the long time reaction, which showed good thermal stability. TEM and BET results showed that the nanoparticle sizes of Pd and NiCo₂O₄ were very small. The XRD patterns indicated that the Pd nanoparticles were highly dispersed on the surface of SiO₂. The XPS spectra demonstrated the formation of NiCO₂O₄, the presence of enough active oxygen species on the catalyst surface and the high ratio of PdO/Pd⁰. The enhanced influence of Ni introduction was also proved by comparison tests. All these results indicated that the high catalytic activity of Pd–NiCo₂O₄/SiO₂ mainly comes from the nanoparticle distribution and the Ni cation enhancement.     

Syngas production by CO2 reforming of coke oven gas over Ni/La2O3–ZrO2 catalysts

Syngas production by CO₂ reforming of coke oven gas (COG) was studied in a fixed-bed reactor over Ni/La₂O₃–ZrO₂ catalysts. The catalysts were prepared by sol–gel technique and tested by XRF, BET, XRD, H₂-TPR, TEM and TG–DSC. The influence of nickel loadings and calcination temperature of the catalysts on reforming reaction was measured. The characterization results revealed that all of the catalysts present excellent resistance to coking. The catalyst with appropriate nickel content and calcination temperature has better dispersion of active metal and higher conversion. It is found that the Ni/La₂O₃–ZrO₂ catalyst with 10 wt% nickel loading provides the best catalytic activity with the conversions of CH₄ and CO₂ both more than 95% at 800 °C under the atmospheric pressure. The Ni/La₂O₃–ZrO₂ catalysts show excellent catalytic performance and anti-carbon property, which will be of great prospects for catalytic CO₂ reforming of COG in the future.     

Thermophysical properties and devitrification of SrO–La2O3–Al2O3–B2O3–SiO2-based glass sealant for solid oxide fuel/electrolyzer cells

Thermal behaviors and stability of glass/glass–ceramic-based sealant materials are critical issues for high temperature solid oxide fuel/electrolyzer cells. To understand the thermophysical properties and devitrification behavior of SrO–La₂O₃–Al₂O₃–B₂O₃–SiO₂ system, glasses were synthesized by quenching (25 − X)SrO–20La₂O₃–(7 + X)Al₂O₃–40B₂O₃–8SiO₂ oxides, where X was varied from 0.0 mol% to 10.0 mol% at 2.5 mol% interval. Thermal properties were characterized by dilatometry and differential scanning calorimetry (DSC). Microstructural studies were performed by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). All the compositions have a glass transition temperature greater than 620 °C and a crystallization temperature greater than 826 °C. Also, all the glasses have a coefficient of thermal expansion (CTE) between 9.0 × 10⁻⁶ K⁻¹ and 14.5 × 10⁶ K⁻¹ after the first thermal cycle. La₂O₃ and B₂O₃ contribute to glass devitrification by forming crystalline LaBO₃. Al₂O₃ stabilizes the glasses by suppressing devitrification. Significant improvement in devitrification resistance is observed as X increases from 0.0 mol% to 10.0 mol%.     

Catalysts of Ni/α-Al2O3 and Ni/La2O3-αAl2O3 for hydrogen production by steam reforming of bio-oil aqueous fraction with pyrolytic lignin retention

This paper reports on the steam reforming, in continuous regime, of the aqueous fraction of bio-oil obtained by flash pyrolysis of lignocellulosic biomass (sawdust). The reaction system is provided with two steps in series: i) thermal step at 200 °C, for the pyrolytic lignin retention, and ii) reforming in-line of the treated bio-oil in a fluidized bed reactor, in the range 600–800 °C, with space-time between 0.10 and 0.45 g_catalyst h (g_bio-oil)⁻¹. The benefits of incorporating La₂O₃ to the Ni/α-Al₂O₃ catalyst on the kinetic behavior (bio-oil conversion, yield and selectivity of hydrogen) and deactivation were determined. The significant role of temperature in gasifying coke precursors was also analyzed. Complete conversion of bio-oil is achieved with the Ni/La₂O₃-αAl₂O₃ catalyst, at 700 °C and space-time of 0.22 g_catalyst h (g_bio-oil)⁻¹. The catalyst deactivation is low and the hydrogen yield and selectivity achieved are 96% and 70%, respectively.     

Hydrogen production from oxidative steam-reforming of n-propanol over Ni/Y2O3–ZrO2 catalysts

Oxidative steam reforming (OSR) of n-propanol was studied over new Ni catalysts (ca. 7% Ni wt/wt) supported on Y₂O₃–ZrO₂ oxides with different yttrium content (2–41 % Y₂O₃ wt/wt). Materials were characterized by X-ray diffraction, temperature-programmed reduction, X-ray photoelectron and Raman spectroscopy, scanning electron microscopy with energy dispersive X-ray analysis and high resolution transmission electron microscopy. Samples were used in calcined form and tested in the temperature range 673–773 K using a reactant feed of n-propanol/water/O₂ at a molar ratio 1/9/0.5. Hydrogen production is related with the support composition and Ni dispersion.