Rational design of three-dimensional porous Ir-supported TiO2–ZrO2 microspheres for low temperature methane combustion

Construction of efficient and stable catalytic combustion materials for the removal of unburnt methane (CH₄) is very critical for both applied environmental catalysis and basic materials research. Herein, a facile hydrothermal approach is designed for the fabrication of Ir/UTZX (Ir/TiO₂–ZrO₂) catalysts. The as-synthesized Ir/UTZX catalysts possess unique sphere morphology as well as electronic structure, leading to enlarged exposure of catalytic sites and enhancement of redox properties. As a result, the representative Ir/UTZ5 catalyst achieves a CH₄ conversion of nearly 100% at 425 °C. Significantly, Ir/UTZ5 displays high long-term stability, with no obvious decrease of catalytic activity in the run of 120 h, which is much higher than those of Ir/TiO₂ and Ir/ZrO₂ catalysts. Our findings offer insights for designing highly efficient and stable catalysts for CH₄ catalytic combustion.     

Molten salt-promoted Ni–Fe/Al2O3 catalyst for methane decomposition

Bimetallic Ni–Fe/Al₂O₃ catalysts were prepared by the molten salt method, and the catalytic performance of the Ni–Fe/Al₂O₃ catalysts with the KCl–NiCl₂ melt for methane decomposition was evaluated at 800 °C. The catalysts and carbon products were characterized by XRD, SEM/EDS, XRF and Raman spectroscopy techniques. The results show that molten salt-promoted Ni–Fe/Al₂O₃ catalysts exhibit high activity and long-term stability up to 1000 min time on stream without any deactivation. The carbon products over the molten salt-promoted Ni–Fe/Al₂O₃ catalysts are in the form of small granular particles instead of filamentous carbon for the catalyst without molten salt. The promotional effect of the molten salt may attribute to the higher wettability of the Fe–Ni alloy by molten salt, which can prevent the catalysts from deactivation due to carbon encapsulation.     

The optimization of Ni–Al2O3 catalyst with the addition of La2O3 for CO2–CH4 reforming to produce syngas

A series of La₂O₃–NiO–Al₂O₃ catalysts promoted by different loading of lanthanum were prepared via the hydrolysis-deposition method to improve the catalytic performance of nickel-based catalyst for CO₂–CH₄ reforming. The catalysts were characterized by N₂ adsorption - desorption, XRD, H₂-TPR, TG-DTG, TEM, Raman and TPH techniques. Results showed that the precursor of active component was mainly in the form of NiAl₂O₄ spinel, which almost disappeared after reduction process from XRD characterization, suggesting well reduction performance. The catalyst with La loading of 0.95 wt% (La–Ni-1) presented a small average Ni grain size of 7.71 nm and exhibited well catalytic performance at 800 °C, with CH₄ conversion of 94.37%, CO₂ conversion of 97.15%, H₂ selectivity of 75.01% and H₂/CO ratio of 0.92. The Ni grain size of La–Ni-1 increased only 5.84% to 8.16 nm after performance test, which was lower than that of others and indicated a well structure stability. Additionally, the strong carbon diffraction peak over La–Ni-0.5 and La–Ni-2 catalysts suggested the presence of crystalline carbon species accumulated on the catalysts, while there was no carbon peak over La–Ni-1 sample. A 150 h stability test for La–Ni-1 demonstrated that the conversion of CH₄ was around 95%, higher than that of La–Ni-0 (without lanthanum addition) and La–Ni-4 (with La content of 3.82 wt%). The carbon deposition rate of La–Ni-1 was only 1.63 mg/(g_cat·h), lower than that of La–Ni-4 (2.20 mg/(g_cat·h)), showing both high activity and well stability. Therefore, the “confinement effect” of La₂O₃ to Ni crystalline grain would inhibit the sintering of active component, prevent the carbon deposition, and improve the catalytic reforming performance.     

Ni–Re alloy catalysts on Al2O3 for methane dry reforming

Methane reforming with CO₂ is still of great interest due to growing demand creating a continuous need for new hydrogen sources. The main difficulty in this reaction is the deactivation of the catalyst due to the formation of carbon deposits on its surface. Herein, a series of commercial nickel catalysts supported on α-Al₂O₃ and modified with different amounts of rhenium (up to 4 wt%) was investigated. It was revealed that Re addition causes the formation of Ni–Re alloy during high temperature reduction, which was confirmed in deep XRD and STEM studies. The addition of Re positively influences not only the stability of the catalyst, but also increases its activity in the DRM reaction carried out in a Tapered Element Oscillating Microbalance (TEOM). The formation of Ni–Re alloy played a significant role in enhancing the properties of the catalyst.     

Promoted Ni–Co–Al2O3 nanostructured catalysts for CO2 methanation

15 wt.%Ni-12.5 wt.%Co–Al₂O₃ catalysts promoted with Fe, Mn, Cu, Zr, La, Ce, and Ba were prepared by a novel solid-state synthesis method and employed in CO₂ methanation reaction. BET, XRD, EDS, SEM, TPR, TGA, and FTIR analyses were conducted to identify the chemicophysical characteristics of the prepared samples. The addition of Fe, Mn, La, Ce, and Ba was effective to improve the catalytic performance of the 15 wt%Ni-12.5 wt%Co–Al₂O₃ due to the higher CO₂ adsorption capacity of the promoted catalysts. Among the studied promoters, the Fe-promoted catalyst possessed the highest catalytic activity (X_CO2 = 61.2% and S_CH4 = 98.87% at 300 °C). Also, the effect of calcination temperature, feed composition, and GHSV on the performance of the 15 wt%Ni-12.5 wt%Co-5wt%Fe–Al₂O₃ catalyst in CO₂ methanation reaction was assessed. The outcomes confirmed that the 15 wt%Ni-12.5 wt%Co-5wt%Fe–Al₂O₃ catalyst with the BET area of 122.4 m²/g and the highest pore volume and largest pore diameter had the highest catalytic activity. Also, the catalytic performance in the methanation of carbon monoxide was studied, and 100% conversion of carbon monoxide was observed at 250 °C.     

Improved hydrogen production performance of Ni–Al2O3/CaO–CaZrO3 composite catalyst for CO2 sorption enhanced CH4/H2O reforming

Bifunctional composite catalysts are very intrigued to produce hydrogen via CO₂ sorption enhanced CH₄/H₂O reforming. However, their hydrogen production performance declined over multiple cycles, owing to the structure collapse and the sintering of active component under high-temperature regeneration. This work reported the facile synthesis of long-lasting Ni–Al₂O₃/CaO–CaZrO₃ composite catalysts with less inert components (36 wt%) for stable hydrogen production over the multiple cycles of CO₂ sorption enhanced CH₄/H₂O reforming. The effects of reaction and regeneration temperature on the hydrogen production performance of Ni–Al₂O₃/CaO–CaZrO₃ were explored. Ni–Al₂O₃/CaO–CaZrO₃ demonstrated high activity and stability while fixing reaction temperature as 600 °C and regeneration temperature as 750 °C. Of particular importance, H₂ concentration was 98 vol% even after 10 hydrogen production cycles due to the inert component CaZrO₃ having a cross-linked structure. The distribution of CaZrO₃ in the composite as a coral-like structure inhibited the sintering of CaO through high Taman temperature and physical separation. Moreover, it provided the skeleton support and pore volume for the repeated expansion and contraction process of CaO to CaCO₃ during the cycling process. Finally, the sintering of Ni slowed down in appropriate regeneration temperature to maintain the structure of the composite catalyst, which further improved the catalyst's stability over multiple cycles.     

Combined steam and CO2 reforming of methane (CSCRM) over Ni–Pd/Al2O3 catalyst for syngas formation

In order to syngas formation, combined steam and carbon dioxide reforming of methane (CSCRM) used in the presence of Ni–Pd/Al₂O₃ catalysts, which were synthesized by the sol-gel method. Al₂O₃ supported Ni–Pd catalyst exhibited the appropriate surface area of 176.2 m²/g and high dispersion of NiO phase with an average crystallite size of 11 nm, which was detected on catalyst surface utilizing transmission electron microscopy (TEM). The influence of three independent operating parameters including reaction temperature in the range of 500–1000 °C; (CO₂ + H₂O)/CH₄ ratio, in the range of 1–3 and CO₂/H₂O ratio; in the range of 1–3, were investigated on the responses (i.e., CH₄ conversion, H₂ yield, CO yield, amount of coke formation on the catalyst surface and H₂/CO ratio) in CSCRM by using response surface methodology–central composite design (RSM-CCD) method. The obtained results from ANOVA and the proposed quadratic models could fine forecast the responses. It was seen that the total methane conversion and CO yield was almost accessible at temperatures higher than 850 °C. Moreover, the CO₂/H₂O ratio exhibited no significant effect on the CH₄ conversion, H₂ yield and CO yield of Ni–Pd/Al₂O₃ catalysts in CSCRM reaction. However, the high CO₂/H₂O ratio in inlet feed led to the syngas formation with a low H₂/CO ratio. The results revealed that lower CO₂/H₂O ratio and higher temperature as well as higher (CO₂ + H₂O)/CH₄ ratio help to decrease the coke formation.     

Effect of sulfur–carbon interaction on sulfur poisoning of Ni/Al2O3 catalysts for hydrogenation

The poisoning effects of two types of carbon-containing sulfides (CS₂ and CH₃SSCH₃) on Ni/Al₂O₃ catalysts for the hydrogenation of benzene and cyclohexene were systematically investigated via experiments and DFT calculations. The toxicity of CH₃SSCH₃ is two and three times greater than that of CS₂ for the hydrogenation of cyclohexene and benzene, respectively. The characterization and DFT results reveal that CH₃SSCH₃ dissociates easily during hydrogenation and releases CH₄, allowing sulfur atoms to poison the Ni sites. However, the presence of CS₂ in the hydrogenation step slows the decline in the catalytic performance, because of resistance to the direct dissociation of the strong CS bond of CS₂. The chemisorbed CS₂ molecules and their incomplete dissociation weaken the strength of NiS bond and decrease the poisoning effect of sulfur. The poisoning processes of two sulfides are also discussed following a DFT study. This work opens up promising possibilities for the industrial study of S-poisoning resistance in supported Ni catalysts.     

Coke-resistance over Rh–Ni bimetallic catalyst for low temperature dry reforming of methane

Methane and carbon dioxide can be converted into syngas using the prospective dry reforming of methane technology. Carbon deposition is a major cause of catalyst deactivation in this reaction, especially at low temperature. The superior stability of bimetallic catalysts has made their development more and more appealing. Herein, a series of bimetallic RhNi supported on MgAl₂O₄ catalysts were synthesized and used for low temperature biogas dry reforming. The results demonstrate that the bimetallic RhNi catalyst can convert CH₄ and CO₂ by up to 43% and 52% over at low reaction temperature (600 °C). Moreover, the reaction rate of CH₄ and CO₂ of RhNi–MgAl₂O₄ remains stable during the 20 h long time stability test, most importantly, there was no obviously carbon deposition observed over the spent catalyst. The enhanced coking resistance should be attributed to the addition of a little amount of noble metal Rh can efficiently suppress dissociation of CH_X1 species into carbon, and the high surface areas of MgAl₂O₄ support can also promote the adsorption and activation of carbon dioxide to generate more O1 species. Balancing the rate of methane dissociation and carbon dioxide activation to inhibit the development of carbon deposition is a good strategy, which provides a guidance for design other high performance dry reforming of methane catalysts.     

Ni/Ru–Mn/Al2O3 catalysts for steam reforming of toluene as model biomass tar

The catalytic steam reforming of the major biomass tar component, toluene, was studied over two commercial Ni-based catalysts and two prepared Ru–Mn-promoted Ni-base catalysts, in the temperatures range 673–1073 K. Generally, the conversion of toluene and the H₂ content in the product gas increased with temperature. A H₂-rich gas was generated by the steam reforming of toluene, and the CO and CO₂ contents in the product gas were reduced by the reverse Boudouard reaction. A naphtha-reforming catalyst (46-5Q) exhibited better performance in the steam reforming of toluene at temperatures over 873 K than a methane-reforming catalyst (Reformax 330). Ni/Ru–Mn/Al₂O₃ catalysts showed high toluene reforming performance at temperatures over 873 K. The results indicate that the observed high stability and coking resistance may be attributed to the promotional effects of Mn on the Ni/Ru–Mn/Al₂O₃ catalyst.     

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.     

Enhanced low temperature catalytic activity of Ni/Al–Ce0.8Zr0.2O2 for hydrogen production from ammonia decomposition

Ammonia decomposition is an effective way for high purity hydrogen production, yet the increase of catalytic activity at low temperatures remains a big challenge for this process. In this paper, a CeO₂–ZrO₂ composite with Al as the secondary dopant was synthesized by the co-precipitation method, which was used as the carrier of nickel metal for ammonia decomposition. The experimental results showed that an obvious increase in catalytic activity of the ammonia decomposition at the relatively low temperature range of 450–550 °C was achieved over the nickel catalyst with CeO₂–ZrO₂ composite as the metal carrier. Specifically, the complete decomposition of ammonia was achieved at 580 °C for Ni/Al–Ce_0.8Zr_0.2O₂ catalyst, while only 92% of ammonia was decomposed at 600 °C over the reference Ni/Al₂O₃ catalyst. The characterization results indicated that the introduction of Al as the secondary dopant of ceria not only increases the specific surface area and oxygen defects on the surface, but also enhances the nickel metal dispersion and metal-support interaction, thus enhances the catalytic performance of Ni/Al–Ce_0.8Zr_0.2O₂ catalyst in the ammonia decomposition.     

Methane thermocatalytic decomposition to COx-free hydrogen and carbon nanomaterials over Ni–Mn–Ru/Al2O3 catalysts

Thermocatalytic decomposition of methane is proposed to be an economical and green method to produce CO_x-free hydrogen and carbon nanomaterials. In this work, the catalytic performance of Ni–Mn–Ru/Al₂O₃ catalyst under different reaction parameters (such as, pre-reduction temperature, reaction temperature, space velocity, etc.) were investigated to obtain optimum reaction conditions. The catalysts were characterized by N₂ adsorption/desorption, X-ray diffraction, inductively coupled plasma optical emission spectrometer and hydrogen temperature programmed reduction. For the 60 wt% Ni-5 wt% Mn-10 wt% Ru/Al₂O₃ catalyst using Ru(NO)(NO₃)_x(OH)_y(x + y = 3) as Ru precursor, the methane conversion rate obtained is high as 93.76% under optimum reaction conditions (reduction at 700 °C for 1 h, reaction at 750 °C, GSHV = 36,000 mL/g_cat h). Carbon nanomaterials formed during the process of methane thermocatalytic decomposition were characterized by scanning electron microscopy, thermal gravimetric analyzer and Raman spectroscopy. Carbon nanofibers were formed over all the Ni–Mn–Ru/Al₂O₃ catalysts.     

Synthetic gas production by dry reforming of methane over Ni/Al2O3–ZrO2 catalysts: High H2/CO ratio

Alumina prepared by the sol-gel method, was impregnated with zirconia (5, 15 and 30 wt.%). Subsequently, the resulting Al₂O₃–ZrO₂ supports were impregnated with 15% Ni to obtain the Ni/Al₂O₃–ZrO₂ catalysts. The obtained catalysts were characterized by BET, SEM, XRD, H₂-TPR and TPD- CO₂. The catalytic activity was studied by means of dry reforming of methane (DRM) for syngas production. The catalysts displayed different physicochemical properties and trends of their catalytic activity as a function of the ZrO₂ content in the mixed oxide supports. For instance, ZrO₂ (5 wt %) in the catalyst, led to enhanced concentration of the medium strength basic sites and increased specific surface area, yielding thus the best performance in the DRM, with low carbon deposition after 36 h of reaction, compared with the other catalysts. This indicates that during the DRM reaction, this catalyst can provide more surface oxygen to prevent carbon deposits that could deactivate the catalyst.     

Study of bimetallic Cu–Ni/γ-Al2O3 catalysts for carbon dioxide hydrogenation

The effect of the Cu/Ni ratio on CO₂ hydrogenation at 773 K and 873 K was studied by XRD, TPR, H₂ and CO₂–TPD. There exists strong interaction between Cu and Ni components. At high temperature (773 K and 873 K), the products are CO, CH₄ and H₂O without CH₃OH formation. The Cu/Ni ratio has a significant effect on the conversion and selectivity. Cu favors CO formation while Ni is of benefit in CH₄ formation.     

Effects of binary Co–Mn oxides promoters on low-temperature catalytic performance of Pd/Al2O3 for methane combustion

Aiming at fabricating high-activity and stable methane combustion catalysts in the dry/wet conditions, Co–Mn binary oxides were employed as promoters to Pd/Al₂O₃ system herein. The introduction of appropriate amount of manganese made Mn³⁺ maximally enter into the Co₃O₄ spinel structure, conducive to the conversion of Co³⁺ to Co²⁺ by Mn³⁺ and then the enhancement of lattice distortion. Therefore, abundant oxygen vacancies were produced, which enhanced the surface-concentrations of active Pd²⁺ and O_ads species, together with the exchange of oxygen species. The resulting catalyst with a molar Mn/Co ratio of 0.20 performed superior low-temperature activity and durability. Moreover, the synergy of Mn and Co could accelerate the removal process of accumulated OH/H₂O from the active sites, thereby promoting the regeneration of PdO and oxygen vacancies. This endowed the tailored catalyst with remarkable moisture-tolerance and hydrothermal stability, and inspiring enhanced activity (T₉₀ = 350 °C) after removing water vapor.     

Catalytic performance of Samarium-modified Ni catalysts over Al2O3–CaO support for dry reforming of methane

Mesoporous calcina-modified alumina (Al₂O₃–CaO) support was produced through the simple and economical co-precipitation method, then nickel (Ni, 10 wt%) and samarium (Sm, 3 wt%) ions loaded by two-solvent impregnation and one-pot strategies. The unpromoted/samarium-promoted catalysts were evaluated using X-ray Diffraction (XRD), High-Resolution Transmission Electron Microscopy (HR-TEM), nitrogen adsorption-desorption, Temperature Programmed Oxidation/Reduction (TPR/TPO), and Field Emission Electron Scanning Microscopy (FE-SEM) methods, then investigated in methane dry reforming. The results revealed that with adding samarium to Ni catalyst through impregnation method, the average Ni crystallite size and specific surface area decreased from 11.5 to 5.75 nm and from 76.08 to 30.9 m²/g, respectively; as a result, the catalytic activity increased from about 50% to 68% at 700 °C. Furthermore, the TPO and FE-SEM tests indicated the formation of carbon with nanotube nature on the catalyst surface.     

One-step synthesis of metallic Ni–C/Al2O3 directly applied for CO2 reforming of CH4

In this work, the vacuum co-impregnation of glucose and nickel precursor followed by the carbonization in an inert gas was developed as a new method for the preparation of the directly reduced Ni-based catalysts (Ni–C/Al₂O₃), which can be directly applied for CO₂ reforming of CH₄ (CRM) without any reduction. The materials were characterized by XRD, TEM, and N₂ adsorption-desorption at low temperature. The results showed that H₂ and CH₄ derived from the decomposition of the glucose acted as the reducing agents for synthesizing metallic Ni from Ni precursors, and the reduction content of nickel was strongly dependent on the amount the glucose. The introduction of carbon derived from decomposition of glucose decreased the interaction between Ni and Al₂O₃ and then resulting in bigger Ni particle. Under the same CRM reaction conditions, the as-prepared Ni-0.35C/Al₂O₃ catalyst without further reduction showed highest catalytic activity and stability. The use of the directly reduced Ni-based catalyst without further high-temperature reduction is promising for the development of a more efficient CRM process.     

Kinetic studies for DRM over high-performance Ni–W/Al2O3–MgO catalyst

The reaction kinetics of DRM over high-performance Ni–W/Al₂O₃–MgO bimetallic catalyst is investigated in a fixed bed reactor. The variation of reaction rate is examined within the CH₄ and CO₂ partial pressure from 0.2 to 0.6 atm and the temperature range of 600^oC–800 °C. It is found that the rate of reaction for DRM is more sensitive to CH₄ partial pressure compared to CO₂ partial pressures. At a constant partial pressure of CO₂ and increasing the CH₄ partial pressure, the increase in the reaction rate is more than reverse conditions. The activation energies of consumption of CH₄ and CO₂ were found to be 45.9 and 31.9 kJ/mol, respectively, showing a higher energy barrier for CH₄ activation than CO2. Four typical kinetic models then fitted the experimental results obtained, i.e., Power Law, Langmuir- Hinshelwood and Eley-Rideal model I and II. The Langmuir-Hinshelwood model showed the best fitting between experimental and estimated reaction rates.     

Solid-state synthesis method for the preparation of cobalt doped Ni–Al2O3 mesoporous catalysts for CO2 methanation

In this study, a simple solid-state synthesis method was employed for the preparation of the Ni–Co–Al₂O₃ catalysts with various Co loadings, and the prepared catalysts were used in CO₂ methanation reaction. The results demonstrated that the incorporation of cobalt in nickel-based catalysts enhanced the activity of the catalyst. The results showed that the 15 wt%Ni-12.5 wt%Co–Al₂O₃ sample with a specific surface area of 129.96 m²/g possessed the highest catalytic performance in CO₂ methanation (76.2% CO₂ conversion and 96.39% CH₄ selectivity at 400 °C) and this catalyst presented high stability over 10 h time-on-stream. Also, CO methanation was investigated and the results showed a complete CO conversion at 300 °C.