Effects of Y2O3-modification to Ni/γ-Al2O3 catalysts on autothermal reforming of methane with CO2 to syngas

The effects of Y₂O₃-modification to Ni/γ-Al₂O₃ catalysts on autothermal reforming of methane to syngas were investigated. It was found that the introduction of Y₂O₃ (5%, 8%, 10%) lead to significant improvement in catalytic activity and stability, and the H₂/CO ratio could be adjusted via controlling the O₂/CO₂ ratio of the feed gas. According to the characterization results of catalysts before and after reaction, it was found that the Y₂O₃·γ-Al₂O₃ supported Ni catalysts had higher NiO reducibility, smaller Ni particle size, higher Ni dispersion and stronger basicity than those of the Ni/γ-Al₂O₃ catalysts. The analysis of catalysts after reaction showed that the addition of Y₂O₃ inhibited the Ni sintering, changed the type of coke and decreased the amount of coke on the catalysts. All the experimental results indicated that the introduction of Y₂O₃ to Ni/γ-Al₂O₃ resulted in excellent catalytic performances in autothermal reforming of methane, and Y₂O₃ played important roles in preventing metal sintering and coke deposition via controlling NiO reducibility, Ni particle size and dispersion, and basicity of catalysts.     

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.     

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.     

Stability of Ni and Rh–Ni catalysts derived from hydrotalcite-like precursors for the partial oxidation of methane

In this work, NiMgAl and RhNiMgAl catalysts prepared from HTLCs precursors were investigated for the Partial Oxidation of Methane (POM) at 550 and 750 °C. Samples have been characterized by XRD, TPR, H₂ chemisorption, TPSR analyses, XPS, field emission scanning electron microscopy and Raman spectroscopy. NiMgAl catalysts with high Ni content (40 and 16 wt%) showed high stability and high methane conversion for POM. On the other hand those with lower Ni content (NiHT15 and NiHT25, with 6 and 4 wt%) exhibited low catalytic activity with low H₂/CO ratio (<2) and fast deactivation. In RhNiHT25 (0.6 wt. % Rh), the Ni reducibility was improved, increasing the methane conversion and hydrogen selectivity. In addition, the noticeable increase in stability was related to the absence of carbon deposition after 30 h on stream at 550 °C. These results show that RhNiHT25 is promising for application in membrane reactors to produce high purity hydrogen.     

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.     

Autothermal syngas production from model gasoline over Ni,Rh and Ni–Rh/Al2O3 monolithic catalysts

On-board reforming of liquid fuels is attractive for fuel cell-powered auxiliary power units in vehicles. In this work, monometallic Ni/Al₂O₃/cordierite, Rh/Al₂O₃/cordierite and bimetallic Ni–Rh/Al₂O₃/cordierite monolithic catalysts were prepared, characterized and tested in ATR of isooctane for syngas production. Compared to monometallic formulations, the bimetallic Ni–Rh/Al₂O₃ catalyst was active for ATR at lower temperature and H₂ production already reached the equilibrium composition in 400–550 °C temperature range. The Ni–Rh/Al₂O₃ catalyst exhibited stable performances for 140 h in ATR of isooctane at 700 °C, and was unaffected by oxidizing conditions at 700 °C. Thermoneutral reactions conditions at H₂O/C = 2 were obtained with O/C = 0.66. Carbon deposition was marginal during ATR of isooctane and no carbons whiskers were detected. Post-reaction characterizations showed that the Ni particles were small enough to prevent filamentous carbon formation, while Rh also prevented carbon film deposition by improving the gasification of adsorbed C with steam.     

Metallic Ni monolith–Ni/MgAl2O4 dual bed catalysts for the autothermal partial oxidation of methane to synthesis gas

A dual bed catalyst system consisting of a metallic Ni monolith catalyst in the front followed by a supported nickel catalyst Ni/MgAl₂O₄ has been studied for the autothermal partial oxidation of methane to synthesis gas. The effects of bed configuration, reforming bed length, feed temperature and gas hourly space velocity on the reaction as well as the stability are investigated. The results show that the metallic Ni monolith in the front functions as the oxidation catalyst, which prevents the exposure of the reforming catalyst in the back to the very high temperature, while the supported Ni/MgAl₂O₄ in the back functions as the reforming catalyst which further increases the methane conversion by 5%. A typical 5 mmNi monolith–5mmNi/MgAl₂O₄ dual bed catalyst exhibits methane conversion and hydrogen and carbon monoxide selectivities of 85.3%, 91.5% and 93.0%, respectively, under autothermal conditions at a methane to oxygen molar ratio of 2.0 and gas hourly space velocity of 1.0 × 10⁵ h⁻¹. The dual bed catalyst system is also very stable.     

Low-temperature partial oxidation of methane over Pd–Ni bimetallic catalysts supported on CeO2

Monometallic Pd and Ni and bimetallic Pd–Ni catalysts supported on CeO₂ are prepared via mechanochemical and conventional incipient wetness impregnation methods and tested for the production of syngas by the partial oxidation of methane. Compared with monometallic Ni/CeO₂ and Pd/CeO₂, bimetallic Pd–Ni/CeO₂ catalysts show considerable higher methane conversion and syngas yield. Additionally, the bimetallic catalysts prepared by ball milling produce syngas at lower temperature. Different preparation parameters, such as metal loading, Pd/Ni ratio, milling energy, milling time and order of incorporation of the metals are examined. The best performance is obtained with a bimetallic catalyst prepared at 50 Hz for 20 min with only 0.12 wt% Pd and 1.38 wt% Ni. Stability tests demonstrate superior stability for bimetallic Pd–Ni/CeO₂ catalysts prepared by a mechanochemical approach. From the characterization results, this is explained in terms of an impressive dispersion of metal species with a strong interaction with the surface of CeO₂.     

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.     

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.     

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.     

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.     

Stability improvements of Ni/α-Al2O3 catalysts to obtain hydrogen from methane reforming

Ni catalysts supported on commercial α-Al₂O₃ modified by addition of CeO₂ and/or ZrO₂ were prepared in the present work. Since the principal objective was to evaluate the behavior of these systems and the support effect on the stability, methane reforming reactions were studied with steam, carbon dioxide, partial oxidation and mixed reforming. Results show that catalysts supported on Ce–Zr–α-Al₂O₃ composites present better reforming activity and stability noticeably higher than in the case of the reference support. With respect to composites, the presence of mixed oxides of Ce_xZr_1−xO₂ type facilitates the formation of active phases with higher interaction. This fact reduces the deactivation by sintering conferring to the system a higher contribution of adsorbed oxygen species, favoring the deposited carbon elimination. These improvements resulted in being dependent on the Ce:Zr ratio of the composite, thus obtaining more stable catalysts for Ce:Zr = 4:1 ratios.     

Hydrogen production by steam reforming of ethanol over P123-assisted mesoporous Ni–Al2O3–ZrO2 xerogel catalysts

A series of mesoporous Ni–Al₂O₃–ZrO₂ xerogel (denoted as X-NAZ) catalysts were prepared by a P123-assisted epoxide-driven sol–gel method under different P123 concentration (X, mM), and they were applied to the hydrogen production by steam reforming of ethanol. The effect of P123 concentration on the physicochemical properties and catalytic activities of X-NAZ catalysts was investigated. All the catalysts retained a mesoporous structure. Pore volume of the catalysts increased with increasing P123 concentration. Ni surface area and ethanol adsorption capacity of X-NAZ catalysts exhibited volcano-shaped trends with respect to P123 concentration. The trend of hydrogen yield was well matched with the trend of Ni surface area and ethanol adsorption capacity. Thus, Ni surface area and ethanol adsorption capacity of the catalysts served as important factors determining the catalytic performance. Among the catalysts tested, 12-NAZ catalyst with the highest Ni surface area and the largest ethanol adsorption capacity showed the best catalytic performance in the steam reforming of ethanol. In conclusion, an optimal P123 concentration was required for maximum production of hydrogen in the steam reforming of ethanol over X-NAZ catalysts.     

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.     

Effects of Fe substitutions by Ni in La–Ni–O perovskite-type oxides in reforming of methane with CO2 and O2

LaNiO₃ and LaNi_1−xFe_xO₃ (x = 0.2, 0.4, 0.6, 0.8 and 1) perovskites were prepared by the citrate sol–gel method. The prepared compounds were characterized by using thermogravimetric analysis (TGA) and X-ray diffraction (XRD), temperature programmed reduction (TPR), and inductively coupled plasma (ICP) techniques. Specific surface area of the samples was measured by BET method. Morphology study of the prepared catalysts was performed using scanning and transmission electron microscopy (SEM and TEM, respectively). The XRD patterns of fresh catalysts indicated the formation of well-crystallized perovskite structure as the main phase present in the prepared samples. The results showed that the highly homogeneous and pure solids with particle sizes in the range of nanometers were obtained through this synthesis method. TPR analysis revealed that by increasing the degree of substitution (x) the reduction of the prepared samples became difficult. The effects of the partial substitution of Ni by Fe and reaction temperatures at atmospheric pressure were investigated in the combined reforming of methane with CO₂ and O₂ (CRM), after reduction of the samples under hydrogen. LaNiO₃ exhibited high activity and selectivity without coke formation between all of the studied perovskites. Among Fe-substituted catalysts, the following order of activity was observed: LaNiO₃>LaNi_0.4Fe_0.6O₃>LaNi_0.6Fe_0.4O₃ > LaNi_0.8Fe_0.2O₃ > LaNi_0.2Fe_0.8O₃ > LaFeO₃.     

Hydrogen production by steam reforming of ethanol over mesoporous Ni–Al2O3–ZrO2 xerogel catalysts: Effect of nickel content

Hydrogen production by steam reforming of ethanol over mesoporous Ni–Al₂O₃–ZrO₂ xerogel catalysts (denoted as XNiAZ) with different nickel content (X, wt%) was studied. A single-step epoxide-driven sol–gel method was employed for the preparation of the catalysts. The effect of nickel content of XNiAZ catalysts on their physicochemical properties and catalytic activities was investigated. All the XNiAZ catalysts exhibited a well-developed mesoporous structure and they dominantly showed an amorphous NiO–Al₂O₃–ZrO₂ composite phase, leading to high dispersion of NiO. Nickel surface area and reducibility of XNiAZ catalysts showed volcano-shaped trends with respect to nickel content. Nickel surface area of XNiAZ catalysts played a key role in determining the catalytic performance in the steam reforming of ethanol; an optimal nickel content was required for maximum production of hydrogen. Among the catalysts tested, 15NiAZ catalyst with the highest nickel surface area exhibited the best catalytic performance in the steam reforming of ethanol. In addition, 15NiAZ catalyst showed high and stable hydrogen yields under different total feed rate, demonstrating its potential applicability in large-scale hydrogen production.     

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%).     

Ni/MgO–Al2O3 and Ni–Mg–O catalyzed SiC foam absorbers for high temperature solar reforming of methane

Ni catalyst supported on MgO–Al₂O₃ (Ni/MgO–Al₂O₃) prepared from hydrotalcite, and Ni–Mg–O catalyst are studied in regard to their activity in the CO₂ reforming of methane at high temperatures in order to develop a catalytically activated foam receiver–absorber for use in solar reforming. First, the activity of their powder catalysts is examined. Ni/MgO–Al₂O₃ powder catalyst exhibits a remarkable degree of high activity and thermal stability as compared with Ni–Mg–O powder catalyst. Secondly, a new type of catalytically activated ceramic foam absorber – Ni/MgO–Al₂O₃/SiC – and Ni–Mg–O catalyzed SiC foam absorber are prepared and their activity is evaluated using a laboratory-scale receiver–reactor with a transparent quartz window and a sun-simulator. The present Ni-based catalytic absorbers are more cost effective than conventional Rh/γ-Al₂O₃ catalyzed alumina and SiC foam absorbers and the alternative Ru/γ-Al₂O₃ catalyzed SiC foam absorbers. Ni/MgO–Al₂O₃ catalyzed SiC foam absorber, in particular, exhibits superior reforming performance that provides results comparable to that of Rh/γ-Al₂O₃ catalyzed alumina foam absorber under a high flux condition or at high temperatures above 1000 °C. Ni/MgO–Al₂O₃ catalyzed SiC foam absorber will be desirable for use in solar receiver–reactor systems to convert concentrated high solar fluxes to chemical fuels via endothermic natural-gas reforming at high temperatures.     

Catalytic partial oxidation of CH4–H2 mixtures over Ni foams modified with Rh and Pt

The catalytic partial oxidation (CPO) of methane–hydrogen mixtures in air, intended for the first stage of hybrid radiant catalytic burners, was investigated under self-sustained short contact time conditions on commercial Ni foam catalysts eventually modified with Rh and Pt. The modified catalysts were prepared by a simple novel method based on the spontaneous deposition of noble metals via metal exchange reactions onto those Ni foam substrates. SEM-EDS, electrochemical methods and H₂-TPR analysis were integrated to characterize morphology, surface area of metal deposits and reducibility of foam catalysts before and after exposure to severe conditions in the CPO reactor. In particular Rh forms finely dispersed deposits that retain their high specific surface area at temperatures up ca. 1100 °C. Modification with noble metals enhances stability and reducibility of the Ni foam whereas the overall CPO performance is not significantly improved. Safe operation of the CPO reactor with up to 70% vol. H₂ in the fuel mixture has been achieved by properly increasing the feed equivalence ratio to avoid catalyst overheating, while guaranteeing high methane conversions and a persistent net hydrogen production.