Improvement of coke resistance of Ni/Al2O3 catalyst in CH4/CO2 reforming by ZrO2 addition

This work investigates the improvement of Ni/Al₂O₃ catalyst stability by ZrO₂ addition for H₂ gas production from CH₄/CO₂ reforming reactions. The initial effect of Ni addition was followed by the effect of increasing operating temperature to 500–700 °C as well as the effect of ZrO₂ loading and the promoted catalyst preparation methods by using a feed gas mixture at a CH₄:CO₂ ratio of 1:1.25. The experimental results showed that a high reaction temperature of 700 °C was favored by an endothermic dry reforming reaction. In this reaction the deactivation of Ni/Al₂O₃ was mainly due to coke deposition. This deactivation was evidently inhibited by ZrO₂, as it enhances dissociation of CO₂ forming oxygen intermediates near the contact between ZrO₂ and nickel where the deposited coke is gasified afterwards. The texture of the catalyst or BET surface area was affected by the catalyst preparation method. The change of the catalyst texture resulted from the formation of ZrO₂–Al₂O₃ composite and the plugging of Al₂O₃ pore by ZrO₂. The 15% Ni/10% ZrO₂/Al₂O₃ co-impregnated catalyst showed a higher BET surface area and catalytic activity than the sequentially impregnated catalyst whereas coke inhibition capability of the promoted catalysts prepared by either method was comparable. Further study on long-term catalyst stability should be made.     

Preparation and thermophysical properties of LaMgAl11O19–Yb3Al5O12 ceramic composites

LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites were prepared by pressureless sintering process at 1700 °C for 10 h in air. The microstructure and thermophysical properties of the composites were characterized by X-ray diffraction, scanning electron microscopy, high-temperature dilatometer and laser flash diffusivity measurements. LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites are composed of magnetoplumbite and garnet structures. LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites exhibit typical linear increase in thermal expansion with the increase of temperature. The measured thermal diffusivity gradually decreases with increasing temperature. Thermal conductivity of LaMgAl₁₁O₁₉–Yb₃Al₅O₁₂ ceramic composites is in the range of 2.6–3.9 W·m⁻¹·K⁻¹ from room temperature to 1200 °C.     

Matrix–filler interactions in polysilazane-derived ceramics with Al2O3 and ZrO2 fillers

Interactions between a poly(vinyl)silazane and Al₂O₃ or Y₂O₃-stabilised ZrO₂ fillers were studied during the fabrication of polysilazane-derived bulk ceramics in order to investigate the influence of oxide fillers on resulting properties. Specimens were produced by coating of the filler powders with the polysilazane, warm-pressing of the resulting composite powders, and pyrolytic conversion in flowing N₂ at various temperatures between 1000 °C and 1400 °C. Significant differences in densification were observed, depending on the filler used. Reactions between the polysilazane-derived matrix and Al₂O₃ or ZrO₂ at temperatures ≥1300 °C resulted in the formation of Si₅AlON₇ or ZrSiO₄, respectively. Reactivity in the polysilazane-derived component was a result of SiO₂ contamination caused primarily by adsorbed species on the filler particle surface. Knowledge of polysilazane/filler interface processes is found to be decisive for the prediction of properties such as shrinkage and porosity, which heavily influence performance of a material.     

Laser stereolithography of ZrO2 toughened Al2O3

Ceramic laser stereolithography is a manufacturing process suitable candidate for the production of complex shape technical ceramics. The green ceramic is produced layer by layer through laser polymerisation of UV curable ceramic suspensions. A number of critical issues deserve attention: high solid loading and low viscosity of the suspensions, high UV reactivity, prevention of interlayer delamination in the green and in the sintered body, good mechanical performance. In this work, ZrO₂-reinforced Al₂O₃ components have been obtained from an acrylic modified zircon loaded with alumina powders. The zircon compound is effective as organic photoactivated resin and allows the dispersion of a high volume fraction of Al₂O₃ powder (up to 50 vol.%) while keeping viscosity at reasonable low values. The zircon compound also represents a liquid ceramic precursor that converts to oxide after burning out of the binder. Thank to the good dispersion of the alumina powder in the zircon acrylate, a uniform dispersion of ZrO₂ submicron particles is obtained after pyrolysis. These are located at the grain boundaries between alumina grains. Formation of both monoclinic and tetragonal ZrO₂ occurs as evidenced by XRD. No delamination occurs in bending tests as evidenced by SEM fractography, satisfactory modulus and strength values were concurrently found.     

Phase diagram of the Al2O3-HfO2-Y2O3 system

The phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system was first constructed in the temperature range 1200-2800 °C. The phase transformations in the system are completed in eutectic reactions. No ternary compounds or regions of appreciable solid solution were found in the components or binaries in this system. Four new ternary and three new quasibinary eutectics were found. The minimum melting temperature is 1755 °C and it corresponds to the ternary eutectic Al₂O₃ + HfO₂ + Y₃Al₅O₁₂. The solidus surface projection, the schematic of the alloy crystallization path and the vertical sections present the complete phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system.     

Dynamic corrosion of Al2O3-ZrO2-SiO2 and Cr2O3-containing refractories by molten frits. Part I: Macroscopic analysis

Manufacturing of enamels and frits has undergone dramatic changes since the 1980s. This has required significant efforts in research and development. Typical compositions of frits for ceramic tiles are silica-based with fluxing agents; some of the components are highly corrosive. Improvements in the production of frits would imply the selection of the most adequate refractories as a function of the chemical composition of the considered frit and the fabrication procedure.The refractories currently used in frit furnaces are Al₂O₃-ZrO₂-SiO₂ (AZS) fused cast materials and Cr₂O₃-based materials. In this work, results on dynamic corrosion studies of AZS and Cr₂O₃-based materials by two ZnO-containing frits are described. Experiments have been performed using the “Merry Go Round” test at ≅1500 °C. Macroscopic results are analysed in terms of the remaining volume after the tests, as usually done in the glass industry. The significance and limits of such an approach are discussed.     

Creep behavior and related structural defects in Al2O3-Ln2O3 (ZrO2) directionally solidified eutectics (Ln = Gd, Er, Y)

The eutectic architecture of “in situ” composites prepared by solidification from the melt in the Al₂O₃-Ln₂O₃ (ZrO₂) systems gives rise to materials with a high creep resistance. With the objective to elucidate the high temperature deformation micro-mechanisms, microstructural features are investigated on crept specimens. Compressive creep experiments have been carried out between 1400 and 1550 °C for various eutectic compositions. Different deformation regimes depending on considered systems and conditions of stress and temperature are revealed. Transmission electron microscopy studies emphasize the activation of different slip systems in the alumina phase and the deformation by dislocation climb processes controlled by bulk diffusion.     

Preparation of UO2/TiO2 composite ceramic fuel by sol gel-press forming method

This paper studies the preparation of UO₂/TiO₂ composite ceramic fuel through sol gel-press forming. The research shows that at 1200–1300 °C, UO₂/TiO₂ composite ceramic grains are small, uniform and compact. Among them, UO₂–0.5 wt%TiO₂ has the highest density and good mechanical strength at 1250 °C.     

Effect of CeO2 addition on densification and microstructure of Al2O3-YSZ composites

Alumina (Al₂O₃) and alumina-yttria stabilized zirconia (YSZ) composites containing 3 and 5 mass% ceria (CeO₂) were prepared by spark plasma sintering (SPS) at temperatures of 1350-1400 °C for 300 s under a pressure of 40 MPa. Densification, microstructure and mechanical properties of the Al₂O₃ based composites were investigated. Fully dense composites with a relative density of approximately 99% were obtained. The grain growth of alumina was inhibited significantly by the addition of 10 vol% zirconia, and formation of elongated CeAl₁₁O₁₈ grains was observed in the ceria containing composites sintered at 1400 °C. Al₂O₃-YSZ composites without CeO₂ had higher hardness than monolithic Al₂O₃ sintered body and the hardness of Al₂O₃-YSZ composites decreased from 20.3 GPa to 18.5 GPa when the content of ZrO₂ increased from 10 to 30 vol%. The fracture toughness of Al₂O₃ increased from 2.8 MPa m^1/2 to 5.6 MPa m^1/2 with the addition of 10 vol% YSZ, and further addition resulted in higher fracture toughness values. The highest value of fracture toughness, 6.2 MPa m^1/2, was achieved with the addition of 30 vol% YSZ.     

Preparation of ceramic nanospheres by CO2 laser vaporization (LAVA)

In order to prepare ceramic nanoparticles by CO₂ laser vaporization (LAVA) coarse ceramic powders (e.g. ZrO₂, Al₂O₃, and TiO₂) were used as raw materials. The raw powder was vaporized into a flowing process gas under normal pressure. Expanding into the gas, the vapor instantly cools down. Gas-phase condensation leads to the formation of nanoscale particles with a composition that corresponds to that of the raw powder. LAVA nanoparticles are chemically pure, spherical, crystalline, exhibit a narrow size distribution, and form merely soft agglomerates. The co-laser vaporization of mixtures of ceramic raw powders allows for the preparation of nanoparticles of multi-phase (e.g. Fe₂O₃-SiO₂) or single-phase (e.g. CaTiO₃) mixed-oxides and dispersion ceramics (e.g. ZrO₂-Al₂O₃). In order to modify the surface of the nanoparticles they can be coated in-process with an organic additive. Thus, the LAVA method allows for the targeted development of a wide range of ceramic nanopowders with tailored properties.     

Precursor effects on ZrW2O8 formation kinetics

The synthesis of ZrW₂O₈ from different kinds of mixtures containing ZrO₂–WO₃, ZrO(NO₃)₂·2H₂O–WO₃, ZrCl₂O·8H₂O–WO₃, and ZrO₂–(NH₄)₁₀W₁₂O₄₁·5H₂O was investigated, and the kinetics was analyzed using JMA equation. It was found that ZrO(NO₃)₂·2H₂O, ZrCl₂O·8H₂O H₂O and (NH₄)₁₀W₁₂O₄₁·5H₂O that were used as inorganic precursors formed ZrO₂ and WO₃ after firing above 500 °C. The content of ZrW₂O₈ obtained by firing the mixtures is influenced by the kinds of precursors as well as mixing methods. The formation rate of ZrW₂O₈ depends on homogeneity related to mixing methods as well as the particle size of starting powders. Phase-pure ZrW₂O₈ is obtained from the ZrCl₂O·8H₂O–WO₃ mixtures at 1200 °C for 4 h, which is much shorter time than in the case of conventional ZrO₂–WO₃ mixtures. In the reaction kinetics of ZrO₂–WO₃ system, the Avrami exponent (n) is ∼0.5 above 1175 °C, indicating that the reaction is controlled by the diffusion-controlled reaction.     

Corrosion mechanisms of Al2O3/MgAl2O4 by V2O5, NiO, Fe2O3 and vanadium slag

The effects of V₂O₅, NiO, Fe₂O₃ and vanadium slag on the corrosion of Al₂O₃ and MgAl₂O₄ have been investigated. The specimens of Al₂O₃ and MgAl₂O₄ with the respective oxides above mentioned were heated at 10 °C/min from room temperature up to three different temperatures: 1400, 1450 and 1500 °C. The corrosion mechanisms of each system were followed by XRD and SEM analyses. The results obtained showed that Al₂O₃ was less affected by the studied oxides than MgAl₂O₄. Alumina was only attacked by NiO forming NiAl₂O₄ spinel, while the MgAl₂O₄ spinel was attacked by V₂O₅ forming MgV₂O₆. It was also observed that Fe₂O₃ and Mg, Ni, V and Fe present in the vanadium slag diffused into Al₂O₃. On the other hand, the Fe₂O₃ and Ca, S, Si, Na, Mg, V and Fe diffused into the MgAl₂O₄ structure. Finally, the results obtained were compared with those predicted by the FactSage software.     

Sintering of glass-added BaZn1/3Nb2/3O3 ceramics

The complex perovskite oxide Ba(Zn_1/3Nb_2/3)O₃ (BZN) has been studied for its attractive dielectric properties which place this material interesting for applications as multilayer ceramics capacitors or hyperfrequency resonators. This material is sinterable at low temperature with combined glass phase–lithium salt additions, and exhibits, at 1 MHz very low dielectric losses combined with relatively high dielectric constant and a good stability of this later versus temperature. The 2 wt.% of ZnO–SiO₂–B₂O₃ glass phase and 1 wt.% of LiF-added BZN sample sintered at 900 °C exhibits a relative density higher than 95% and attractive dielectric properties: a dielectric constant ?_r of 39, low dielectrics losses (tan(δ) < 10⁻³) and a temperature coefficient of permittivity τ_? of 45 ppm/°C⁻¹. The 2 wt.% ZnO–SiO₂–B₂O₃ glass phase and 1 wt.% of B₂O₃-added BZN sintered at 930 °C exhibits also attractive dielectric properties (?_r = 38, tan(δ) < 10⁻³) and it is more interesting in terms of temperature coefficient of the permittivity (τ_? = −5 ppm/°C). Their good dielectric properties and their compatibility with Ag electrodes, make these ceramics suitable for L.T.C.C applications.     

Preparation of nanocrystalline Sr3Al2O6 powders via citric acid precursor

Sr₃Al₂O₆ was synthesized via citric acid precursor. The effects of the molar ratio of citric acid to total metal cations concentration (CA/M) on the formation of Sr₃Al₂O₆ were investigated. Increasing the CA/M promoted the formation of Sr₃Al₂O₆. Single-phase and well-crystallized Sr₃Al₂O₆ was obtained from the CA/M = 1, CA/M = 2 and CA/M = 4 precursor at temperature 1200 °C, 1100 °C and 900 °C, respectively. Differential thermal analysis and thermogravimetric (DTA/TG), X-ray diffractometry (XRD) and field emission scanning electron microscopy (FESEM) were used to characterize the precursors and the derived oxide powders. Sr₃Al₂O₆ nanoparticles with a diameter of about 50-70 nm were obtained.     

Enhancement of oxygen storage capacity by reductive treatment of Al2O3 and CeO2–ZrO2 solid solution nanocomposite

Oxygen storage capacity (OSC) of CeO₂–ZrO₂ solid solution, Ce_xZr_(1−x)O₄, is one of the most contributing factors to control the performance of an automotive catalyst. To improve the OSC, heat treatments were employed on a nanoscaled composite of Al₂O₃ and CeZrO₄ (ACZ). Reductive treatments from 700 to 1000 °C significantly improved the complete oxygen storage capacity (OSC-c) of ACZ. In particular, the OSC-c measured at 300 °C reached the theoretical maximum with a sufficient specific surface area (SSA) (35 m²/g) after reductive treatment at 1000 °C. The introduced Al₂O₃ facilitated the regular rearrangement of Ce and Zr ions in CeZrO₄ as well as helped in maintaining the sufficient SSA. Reductive treatments also enhanced the oxygen release rate (OSC-r); however, the OSC-r variation against the evaluation temperature and the reduction temperature differed from that of OSC-c. OSC-r measured below 200 °C reached its maximum against the reduction temperature at 800 °C, while those evaluated at 300 °C increased with the reduction temperature in the same manner as OSC-c.     

Dynamic corrosion of Al2O3-ZrO2-SiO2 and Cr2O3-containing refractories by molten frits. Part II: Microstructural study

In this work results on dynamic corrosion studies of fused cast Al₂O₃-SiO₂-ZrO₂ and isostatically pressed and sintered Cr₂O₃-based refractories by two crystalline (transparent) frits are described. Experiments have been performed using the “Merry Go Round” test at ≅1500 °C.Microstructural and mineralogical analyses of selected areas from the corroded regions of the studied refractories were performed by reflected light optical microscopy and scanning electron microscopy with analysis by X-ray dispersive energy.Significant differences between the corrosion mechanisms acting in the two types of materials were found. In the fused cast Al₂O₃-SiO₂-ZrO₂ specimens corrosion took place by the dissolution of alumina and zirconia in the frit and in the glass formed by the reaction between the frit and the refractory. In the Cr₂O₃-based materials the corrosion process was controlled by the capillar penetration of the molten frit through the open pores. The reaction between the ZnO from the frits and Cr₂O₃ led to the formation of spinel (ZnCr₂O₄), a high-melting point bonding phase that retarded the frit penetration. Results are discussed using the relevant phase equilibrium diagrams.     

Sintering of Al2O3-SiC composite from sol-gel method with MgO, TiO2 and Y2O3 addition

Al₂O₃-SiC composite ceramics were prepared by pressureless sintering with and without the addition of MgO, TiO₂ and Y₂O₃ as sintering aids. The effects of these compositional variables on final density and hardness were investigated. In the present article at first α-Al₂O₃ and β-SiC nano powders have been synthesized by sol-gel method separately by using AlCl₃, TEOS and saccharose as precursors. Pressureless sintering was carried out in nitrogen atmosphere at 1600 °C and 1630 °C. The addition of 5 vol.% SiC to Al₂O₃ hindered densification. In contrast, the addition of nano MgO and nano TiO₂ to Al₂O₃-5 vol.% SiC composites improved densification but Y₂O₃ did not have positive effect on sintering. Maximum density (97%) was achieved at 1630 °C. Vickers hardness was 17.7 GPa after sintering at 1630 °C. SEM revealed that the SiC particles were well distributed throughout the composite microstructures. The precursors and the resultant powders were characterized by XRD, STA and SEM.     

Microstructural relationship with fracture toughness of undoped and rare earths (Y, La) doped Al2O3–ZrO2 ceramic composites

Ceramic composites in undoped Al₂O₃–5 wt% ZrO₂ (AZ) and doped with rare earth elements Y, La separately and simultaneously were prepared by solid state sintering process. These composites were characterized for microstructural investigation and determination of phase formation to draw a possible relationship between these characterization results with the fracture toughness measured by single-edge precracked beam (SEPB) test method using three-point bend test. The fracture toughnesses of Y and Y + La doped AZ are found to be higher for samples sintered at 1700 °C for long soaking times, than that of La doped and undoped AZ composites. It is predicted from the XRD and EDS analyses that the phases of Zr_0.88Y_0.12O_1.94 and Zr_0.935Y_0.065O_1.968 are formed at or near the intergranular region and therefore the higher fracture toughness of Y and Y + La doped AZ composites compared to undoped AZ and La doped AZ composite for samples sintered at 1700 °C for long soaking times, is attributed to these intergranular phases.     

Hydrogen production by steam reforming of LNG over Ni/Al2O3-ZrO2 catalysts: Effect of ZrO2 and preparation method of Al2O3-ZrO2

An Al₂O₃-ZrO₂ support was prepared by grafting a zirconium precursor onto the surface of commercial γ-Al₂O₃. A physical mixture of Al₂O₃-ZrO₂ was also prepared for the purpose of comparison. Ni/Al₂O₃-ZrO₂ catalysts were then prepared by an impregnation method, and were applied to the hydrogen production by steam reforming of liquefied natural gas (LNG). The effect ZrO₂ and preparation method of Al₂O₃-ZrO₂ on the performance of supported nickel catalysts in the steam reforming of LNG was investigated. The Al₂O₃-ZrO₂ prepared by a grafting method was more efficient as a support for nickel catalyst than the physical mixture of Al₂O₃-ZrO₂ in the hydrogen production by steam reforming of LNG. The well-developed tetragonal phase of ZrO₂ and the high dispersion of ZrO₂ on the surface of γ-Al₂O₃ were responsible for the enhanced catalytic performance of Ni/Al₂O₃-ZrO₂ prepared by way of a grafting method.     

Large-scale fine structural alumina matrix ceramic guideway materials improved by diopside and Fe2O3

Diopside and Fe₂O₃ were introduced in alumina matrix ceramic materials. Large-scale fine structural alumina matrix ceramic guideway materials were fabricated by the technology of pressureless sintering, during which liquid phase sintering took place and new phases such as 3Al₂O₃·2SiO₂, CaO·Al₂O₃·2SiO₂ and CaO·6Al₂O₃ were produced by the chemical reactions taking place among alumina and the additives. The hardness, the fracture toughness and the bending strength of the guideway products were tested. The influences of diopside and Fe₂O₃ additions were studied by microstructural observations and mechanical properties evaluations. Meanwhile, the expected improvement of mechanical properties compared with pure alumina was indeed observed. The fracture mechanism and porosity of large-scale fine structural alumina matrix ceramic guideway materials were analyzed.