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.     

Performance of Ni catalyst supported on La-hexaaluminate in CO<Subscript>2</Subscript> reforming of CH<Subscript>4</Subscript>

CO₂ reforming of CH₄ was performed using Ni catalyst supported on La-hexaaluminate which has been an well-known material for high-temperature combustion. La-hexaaluminate was synthesized by sol-gel method at various conditions where different amount of Ni (5–20 wt%) was loaded. Ni/La-hexaaluminate experienced 72 h reaction and its catalytic activity was compared with that of Ni/Al₂O₃, Ni/La-hexaaluminate shows higher reforming activity and resistance to coke deposition compared to the Ni/Al₂O₃ model catalyst. Coke deposition increases proportionally to Ni content. Consequently, Ni(5)/La-hexaaluminate(700) is the most efficient catalyst among various Ni/La-hexaaluminate catalysts regarding the cost of Ni in Ni(X)/La-hexaaluminate catalysts. BET surface area, XRD, EA, TGA and TPO were performed for surface characterization. This work was presented at the 6 ^th Korea-China Workshop on Clean Energy Technology held at Busan, Korea, July 4–7, 2006.     

Hydrogen Production by Steam Reforming of Commercially Available LPG in UAE

Steam reforming of commercially available LPG using Ru/Al₂O₃ and Ni/Al₂O₃ catalysts has been studied at temperatures between 573 and 773 K. Ru/Al₂O₃ catalyst showed higher rates of reaction and lower activation energies of the three main components of LPG, compared with Ni/Al₂O₃. However, Ni/Al₂O₃ catalyst showed a better H₂:CH₄ selectivity. The activation energy of n-butane was the lowest over Ru/Al₂O₃, whereas over Ni/Al₂O₃, propane had the lowest activation energy. The activation energy of i-butane was always the highest over both catalysts, which suggests that both catalysts performed better with unbranched molecules. A slight increase in activation energy was observed, when each component of the LPG mixture was studied separately as a pure gas, compared with being mixed in LPG. At a constant temperature of 773 K, hydrogen production yield and H₂:CH₄ selectivity were determined using Ru/Al₂O₃ at different steam:carbon (S:C) ratios and LPG flow rates. It was found that the yield and selectivity increased with the increase in S:C ratio and the decrease in the flow rate. The highest yield of 0.64 was achieved using S:C ratio of 6.5 and a LPG flow rate of 50 mL min^?1. The work provides valuable information on steam reforming of pure components of LPG, compared with when they are in the mixture. The comparison is done using conventional steam reforming catalyst, Ni/Al₂O₃, and compared with Ru/Al₂O₃. The observed trends and variations in reaction rates, in pure and mixed gases, indicated that the mechanism of steam reforming of a hydrocarbon mixture depends on its composition.     

Influence of preparation method on performance of Cu(Zn)(Zr)-alumina catalysts for the hydrogen production via steam reforming of methanol

The selective production of hydrogen via steam reforming of methanol (SRM) was performed using prepared catalysts at atmospheric pressure over a temperature range 200–260^∘C. Reverse water gas shift reaction and methanol decomposition reactions also take place simultaneously with the steam reforming reaction producing carbon monoxide which is highly poisonous to the platinum anode of PEM fuel cell, therefore the detailed study of effect of catalyst preparation method and of different promoters on SRM has been carried out for the minimization of carbon monoxide formation and maximization of hydrogen production. Wet impregnation and co-precipitation methods have been comparatively examined for the preparation of precursors to Cu(Zn)(Al₂O₃) and Cu(Zn)(Zr)(Al₂O₃). The catalyst preparation method affected the methanol conversion, hydrogen yield and carbon monoxide formation significantly. Incorporation of zirconia in Cu(Zn)(Al₂O₃) catalyst enhanced the catalytic activity, hydrogen selectivity and also lower the CO formation. Catalyst Cu(Zn)(Zr)(Al₂O₃) with composition Cu/Zn/Zr/Al:12/4/4/80 prepared by co-precipitation method was the most active catalyst giving methanol conversion up to 97% and CO concentration up to 400 ppm. Catalysts were characterized by atomic absorption spectroscopy (AAS), Brunauer-Emett-Teller (BET) surface area, pore volume, pore size and X-ray powder diffraction (XRPD). The XRPD patterns revealed that the addition of zirconia improves the dispersion of copper which resulted in the better catalytic performance of Cu(Zn)(Zr)(Al₂O₃). The time-on-stream (TOS) catalysts stability test was also conducted for which the Cu(Zn)(Zr)(Al₂O₃) catalyst gave the consistent performance for a long time compared to other catalysts.     

CH4-CO2 reforming over Ni/Al2O3 aerogel catalysts in a fluidized bed reactor

Ni/Al₂O₃ aerogel catalysts were synthesized by a sol-gel method combined with a supercritical drying route. The catalytic performances of the catalysts in methane reforming with CO₂ were investigated in a quartz micro-reactor. The results indicated that the aerogel catalyst showed higher specific surface area and higher dispersivity of nickel species than those of impregnation catalyst. The excellent catalytic performances and stabilities were achieved over the aerogel catalysts in the fluidized bed reactor. Comprehensive characterization with TG, XRD and FESEM revealed that the aerogel catalyst in the fluidized bed had much lower carbon deposition than that in the fixed bed. The fluidization of the aerogel catalyst greatly improved the contact efficiency of gas-solid phase, which accelerated the gasification of the deposited carbon. In contrast, the deactivation of the aerogel catalyst was caused by the carbon deposition due to the catalyst without moving in the fixed bed. Moreover, decreasing activity of the impregnation catalyst in the fluidized bed resulted from the poor fluidization state of catalyst particles and low effective active sites on surface of catalyst.     

Characterization of aerogel Ni/Al2O3 catalysts and investigation on their stability for CH4-CO2 reforming in a fluidized bed

The CH₄-CO₂ reforming was investigated in a fluidized bed reactor using nano-sized aerogel Ni/Al₂O₃ catalysts, which were prepared via a sol–gel method combined with a supercritical drying process. The catalysts were characterized with BET, XRD, H₂-TPR and H₂-TPD techniques. Compared with the impregnation catalyst, aerogel catalysts exhibited higher specific surface areas, lower bulk density, smaller Ni particle sizes, stronger metal-support interaction and higher Ni dispersion degrees. All tested aerogel catalysts showed better catalytic activities and stability than the impregnation catalyst. Their catalytic stability tested during 48 h reforming was dependent on their Ni loadings. Characterizations of spent catalysts indicated that only limited graphitic carbon formed on the aerogel catalyst, while massive graphitic carbon with filamentous morphology was observed for the impregnation catalyst, leading to significant catalytic activity degradation. An aerogel catalyst containing 10% Ni showed the best catalytic stability and the lowest rate of carbon deposition among the aerogel catalysts due to its small Ni particle size and strong metal-support interaction.     

Doped Ni Catalysts for Methane Reforming with CO<Subscript>2</Subscript>

Pb, Sb, Bi and Te doped Ni catalysts were prepared and used for methane reforming with CO₂ in order to diminish coke deposition. It was found that small amounts of Pb doped Ni catalysts exhibited excellent coke resistance ability with minor loss of the reforming activity. As the added amount of Pb increased from 0 to 0.015 (mole ratio between Pb/Ni), coke formation rate decreased from 166.7 mg-coke/g-cat h (on Ni/SiO₂) to 0, while the reforming activity decreased slightly from 73.2% to 63.3% (conversion of CO₂) at 800 °C, 60,000 ml(STP)/g-cat·h (CH₄ CO₂=1:1, no dilution gas in feed). Higher amounts of Pb and Sb, Bi, Te made Ni catalyst deactivated for methane reforming with CO₂.     

Production of hydrogen by steam reforming of bio-oil over Ni/Al2O3 catalysts: Effect of addition of promoter and preparation procedure

Catalytic steam reforming of bio-oil was investigated in a fixed bed tubular reactor for production of hydrogen. Two series of nickel/alumina (Ni/Al₂O₃) supported catalysts promoted with ruthenium (Ru) and magnesium (Mg) were prepared. Each catalyst of the first series (Ru–Ni/Al₂O₃) was prepared by co-impregnation of nickel and ruthenium on alumina. They were examined to investigate the effect of adding ruthenium on the performance of the catalysts for hydrogen production. The effect of the temperature, the most effective parameter in the steam reforming of bio-oil, on the activity of the catalysts was also investigated. Each catalyst of the second series (Ni–MgO/Al₂O₃) was prepared by consecutive impregnation using various preparation procedures. They were tested to determine the effect of adding magnesium as well as the effect of the preparation procedure on the outlet gas concentrations. It was shown that in both series, the catalysts were more efficient in hydrogen production as well as carbon conversion than Ni/Al₂O₃ catalysts. The highest hydrogen yield was 85% which was achieved over Ru–Ni/Al₂O₃ at 950 °C. It was also found that the effect of adding a small amount of ruthenium was superior to that of nickel on the yield of hydrogen when the nickel content was equal to or greater than 10.7%.     

Partial Oxidation Reforming Catalyst for Fuel Cell-Powered Vehicles Applications

Transition metal oxide formulations for the partial oxidation (POX) reforming of isooctane were investigated for an onboard gasoline fuel processor. Ni/M/MgO/Al₂O₃ systems are more active than a commercial ICI catalyst. These catalysts showed better sulfur tolerance over the commercial ICI catalyst in the POX reforming of isooctane containing sulfur (Cs = 100 ppm). There was no apparent deactivation or modification of structure during 770h onstream. It was found that Ni/(Fe,Co)/MgO/Al₂O₃ catalyst is a promising candidate as POX reforming catalyst for gasoline fuel processor applications.     

Investigating the effect of metal oxide additives on the properties of Cu/ZnO/Al2O3 catalysts in methanol synthesis from syngas using factorial experimental design

The Cu/ZnO/Al₂O₃ catalysts, prepared by co-precipitation method, have been modified by adding small amount of Mn, Mg, Zr, Cr, Ba, W and Ce oxides using design of experiments (1/16 full factorial design). The structure and morphology of catalysts were studied by X-ray diffraction (XRD) and BET. Performance of the prepared catalysts for CO/CO₂ hydrogenation to methanol was evaluated by using a stainless steel fixed-bed reactor at 5 MPa and 513 K. The oxide additives were found to influence the catalytic activity, dispersion of Cu, Cu crystallite size, surface composition of catalyst and stability of catalysts during their operations. The results showed that the Mn and Zr promoted catalysts have high performance for methanol synthesis from syngas.     

Ethanol steam reforming reactions over Al2O3 · SiO2-supported Ni-La catalysts

Nickel-based catalysts supported on Al₂O₃ · SiO₂ were prepared with modification of the second metal involving La, Co, Cu, Zr or Y, of which the catalytic behaviors were assessed in the ethanol steam reforming reaction. Activity test indicated that addition of La resulted in higher selectivity of hydrogen and lower selectivity of carbon monoxide, compared with Co-doped nickel catalyst. Influences of lanthanum amounts on catalytic performance were studied over 30NixLa/Al₂O₃ · SiO₂ (x = 5, 10, 15), and characterizations by XRD, TPR and XPS indicated that low amount of lanthanum additives (5%) was superior to inhibit the crystal growth of nickel as well as beneficial to the reduction of nickel oxide. Finally 100 h test for the optimal catalyst 30Ni5La/Al₂O₃ · SiO₂ indicated its good long-term stability to provide high hydrogen selectivity and low carbon monoxide formation, as well as good resistance to coke deposition at low temperature.     

Supported Cu Catalysts with Yttria-Doped Ceria for Steam Reforming of Methanol

The steam reforming of methanol was studied over Cu/Al₂O₃ catalysts with the addition of yttria-doped ceria (YDC). The YDC-modified catalysts were prepared by impregnating a -Al₂O₃ support with Y and Ce then with Cu. The addition of YDC drastically enhanced the activity of Cu/Al₂O₃ in the methanol reforming reaction. The enhanced activity was attributed to the increase of Cu⁺ species by YDC in the methanol reforming environment. However, the addition of YDC decreased the copper dispersion. The Cu dispersion could be enhanced by adding chromium oxide. The addition of YDC and Cr where Al₂O₃ was first impregnated with Cr then with YDC showed the most pronounced enhancement of the catalyst activity. At reaction temperatures of 200250 °C, the CO concentration in the products was smaller than 0.1%.     

CO2 Hydrogenation to Methanol Over Cu/ZnO/Al2O3 Catalysts Prepared by a Novel Gel-Network-Coprecipitation Method

A novel gel-network-coprecipitation process has been developed to prepare ultrafine Cu/ZnO/Al₂O₃ catalysts for methanol synthesis from CO₂ hydrogenation. It is demonstrated that the gel-network-coprecipitation method can allow the preparation of the ultrafine Cu/ZnO/Al₂O₃ catalysts by homogeneous coprecipitation of the metal nitrate salts in the gel network formed by gelatin solution, which makes the metallic copper in the reduced catalyst exist in much smaller crystallite size and exhibit a much higher metallic copper-specific surface area. The effect of the gel concentration of gelatin on the structure, morphology and catalytic properties of the Cu/ZnO/Al₂O₃ catalysts for methanol synthesis from hydrogenation of carbon dioxide was investigated. The Cu/ZnO/Al₂O₃ catalysts prepared by the gel-network-coprecipitation method exhibit a high catalytic activity and selectivity in CO₂ hydrogenation to methanol.     

The role of nickel in pyridine hydrodenitrogenation over NiMo/Al2O3

Al₂O₃ supported Mo, Ni, and NiMo/Al₂O₃ catalysts with various Ni contents were prepared to investigate the role of Ni as a promoter in a NiMo bimetallic catalyst system. The hydrodenitrogenation (HDN) reaction of pyridine as a catalytic probe was conducted over these catalysts under the same reaction conditions and the catalysts were characterized using BET surface area measurement, infrared spectroscopy, temperature programmed reduction, DRS and ESR. According to the results of reaction experiments, the NiMo/Al₂O₃ catalyst showed higher activity than Mo/Al₂O₃ catalyst in the HDN reaction and particularly the one with atomic ratio [Ni/(Ni+Mo)]=0.3 showed the best activity for the HDN of pyridine. The findings of this study lead us to suggest that the enhancement in the HDN activity with nickel addition could be attributed to the improvement in the reducibility of molybdenum and the formation of Ni-Mo-O phase.     

CO Adsorbed Infrared Spectroscopy Study of Ni/Al2O3 Catalyst for CO2 Reforming of Methane

CO adsorbed infrared spectroscopy study was conducted in this work in order to better understand the significantly improved anti-coke performance of Ni/Al₂O₃ catalyst obtained via argon glow discharge plasma treatment. The present study revealed a significant decrease of linear to bridge (L/B) adsorbed CO for glow discharge plasma treated Ni/Al₂O₃, compared to that for untreated Ni/Al₂O₃, indicating an enhancement of close packed plane concentration. This structure change leads to lower methane turnover frequency (TOF) and better balance of carbon formation-gasification, resulting in better anti-coke property of Ni/Al₂O₃ for CO₂ reforming of methane.     

A crucial role of O2 and O2 on mayenite structure for biomass tar steam reforming over Ni/Ca12Al14O33

Newly synthesized nickel calcium aluminum catalysts (Ni/Ca₁₂Al₁₄O₃₃) were tested in a fixed bed reactor for biomass tar steam reforming, toluene as tar destruction model compound. Four catalysts (Ni/Ca₁₂Al₁₄O₃₃) were prepared with Ni loading amount from 1, 3, 5 to 7 wt%, even 1% loading catalyst also showed excellent performance. Catalysts aged experiments in the absence (60 h on stream) and presence of H₂S were characterized by BET, X-ray diffraction (XRD), and Raman spectra. It was observed that Ni/Ca₁₂Al₁₄O₃₃ showed excellent sustainability against coke formation due to the “free oxygen” in the catalysts. It also exhibited higher H₂S-poisoning resistance property compared to the commercial catalysts Ni/Al₂O₃ (5%) and Ni/CaO_0.5/MgO_0.5. Raman spectra revealed that “free oxygen O₂⁻ and O₂²⁻” in the structure of the catalysts could be substituted by sulfur then protected Ni poisoning on some degree, but reactivation experiments by O₂ flowing showed that the sulfide Ni/Ca₁₂Al₁₄O₃₃ was difficult to completely restore, incorporation of sulfur in the structure only partly regain by O₂. The kinetic model proposes, as generally accepted, a first-order reaction for toluene with activation energy of 82.06 kJ mol⁻¹ was coincident with the literature data. The Ni/Ca₁₂Al₁₄O₃₃ catalyst was effective and relative cheap, which may be lead to reduction in the cost of hot gas cleaning process.     

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

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

Correlation of the deactivation of CoMo/Al2O3 in hydrodesulfurization with surface carbon species

The deactivation of CoMo/Al₂O₃ in the hydrodesulfurization (HDS) of dibenzothiophene (DBT) was investigated under laboratory conditions that allowed the accelerated deposition of coke on the catalyst. The coke deposition was enhanced at low H₂ pressures and when naphthalene was added to the reaction solution. Characterization of deactivated catalysts by elemental analysis (EA) and temperature-programmed oxidation (TPO) identified two types of carbonaceous species deposited on the catalysts, the reactive and the refractory species. The refractory deposit, or hard coke, was a major contributor to the deactivation and, therefore, the amounts of hard coke present on the catalyst determined the overall activity. A correlation was established in this study between the activity and the amounts of deposited hard coke based on the results of accelerated deactivation treatment. A similar relation was also observed between the two parameters when the catalyst was used in an industrial process for long periods. The above findings suggest that the reaction periods of two different scales, i.e., in laboratory and industrial processes, can be correlated with each other based on the amounts of hard coke when coking is the major mechanism of catalyst deactivation.     

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

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

Characterization of Sn doped Ni/Al2O3 steam reforming catalysts by XPS

XPS measurements have shown that tin oxides are more readily reduced to metallic tin by hydrogen in Ni/Al₂O₃ systems than on pure Al₂O₃. During the reductive activation of Sn doped Ni/Al₂O₃ catalysts, surface segregation of the dopant was observed. This finding may explain that tin enhances the selectivity of the steam reforming catalysts only when added in very low concentrations and that it acts as a poison at higher loadings.