A comparative study of Ni catalysts supported on Al2O3, MgO–CaO–Al2O3 and La2O3–Al2O3 for the dry reforming of ethane

CO₂ utilization through the activation of ethane, the second largest component of natural and shale gas, to produce syngas, has garnered significant attention in recent years. This work provides a comparative study of Ni catalysts supported on alumina, alumina modified with CaO and MgO, as well as alumina modified with La₂O₃ for the reaction of dry ethane reforming. The calcined, reduced and spent catalysts were characterized employing XRD, N₂ physisorption, H₂-TPR, CO₂-TPD, TEM, XPS and TPO. The modification of the alumina support with alkaline earth oxides (MgO and CaO) and lanthanide oxides (La₂O₃), as promoters, is found to improve the dispersion of Ni, enhance the catalyst's basicity and metal-support interaction, as well as influence the nature of carbon deposition. The Ni catalyst supported on modified alumina with La₂O₃ exhibits a relatively stable syngas yield during 8 h of operation, while H₂ and CO yields decrease substantially for Ni/Al₂O₃.     

Ni/La2O3 and Ni/MgO–La2O3 catalysts for the decomposition of NH3 into hydrogen

The decomposition of NH₃ for hydrogen production was studied using Ni/La₂O₃ catalysts at varying compositions and temperatures prepared via surfactant-templated synthesis to elucidate the influence of catalyst active metal content, support composition and calcination temperature on the catalytic activity. The catalytic performance of all samples was studied between 300 and 600 °C under atmospheric pressure. The catalytic activity of the sample were as follows: 10Ni/La₂O₃-450 > 10Ni/La₂O₃-550 > 10Ni/La₂O₃-650 ≈ 10Ni/La₂O₃-750 ≈ 10Ni/La₂O₃-850. The excellent activity (100%) of 10Ni/La₂O₃-450 could be due to the high surface area, basicity strength and concentration of surface oxygen species of the catalyst as evidenced by BET, CO₂-TPD and XPS. In addition, to adjust the activity of the catalyst support, the molar ratios of Mg and La were varied (1:1, 3:1, 5:1, 7:1 and 9:1). The 5Ni/5MgLa (5:1 M ratio) was found to be the most active (100%) relative to other Ni/MgLa formulations. Furthermore, the Ni content in the Ni/5MgLa sample was adjusted between 10 and 40 wt%. Increasing the Ni content of the catalysts increased NH₃ conversion with the 40 wt% Ni formulation demonstrating complete NH₃ conversion at 600 °C and a high gas hourly space velocities (GHSV) (30,000 mL∙h⁻¹∙g_cat⁻¹).     

The effect of different atmosphere treatments on the performance of Ni/Nb–Al2O3 catalysts for methane steam reforming

Methane steam reforming is currently the most widely used hydrogen production reaction in industry today. Ni/Nb–Al₂O₃ catalysts were prepared by treatment under H₂, N_2, and air atmosphere prior to reduction and applied for methane steam reforming reaction at low temperature (400–600 °C). The hydrogen-treated catalysts increased catalytic activity, with 55.74% methane conversion at S/C = 2, GSVH of 14400 mL g^?1 h^?1 and 550 °C. The H₂ atmosphere treatment enhanced the Ni–Nb interaction and the formation of stable, tiny, homogeneous Ni particles (6 nm), contributing to good activity and stability. In contrast, the catalysts treated with nitrogen and air showed weaker interactions between Ni and Nb species, whereas the added Nb covered the active sites, which caused the decrease in activity. Meanwhile, carbon accumulation was also observed. This work is informative for preserving small nano-sized nickel particles to enhance catalytic performance.     

The deactivation effect of Na2O and NaCl on CeO2–TiO2 catalysts for selective catalytic reduction of NO with NH3

The effect of Na₂O and NaCl on CeO₂–TiO₂ catalyst for the selective catalytic reduction of NO with NH₃ was investigated with BET, XRD, XPS, NH₃-TPD, H₂-TPR, in-situ DRIFT and catalytic activity measurements. The results showed that both Na species could deactivate the CeO₂–TiO₂ catalyst and Na₂O had a stronger effect than NaCl. The more serious deactivation by Na₂O could be ascribed to smaller surface area, fewer surface Ce³⁺ and chemical adsorbed oxygen, lower surface acidity, and worse reducibility. The introduction of NaCl and Na₂O facilitated the formation of new surface NO_x adspecies, but were inactive in NH₃-SCR reaction. The adsorption of NH₃ were inhibited. The NH₃-SCR reaction over the CeO₂–TiO₂ catalyst was governed by both E-R and L-H mechanisms. The introduction of NaCl and Na₂O didn't change the NH₃-SCR reaction mechanisms.     

Effects of CaO addition on Ni/CeO2–ZrO2–Al2O3 coated monolith catalysts for steam reforming of N-decane

A series of 10 wt%Ni/CeO₂–ZrO₂–Al₂O₃ (10%Ni/CZA) coated monolith catalysts modified by CaO with the addition amount of 1 wt%~7 wt% are prepared by incipient-wetness co-impregnation method. Effects of CaO promoter on the catalytic activity and anti-coking ability of 10%Ni/CZA for steam reforming of n-decane are investigated. The catalysts are characterized by N₂ adsorption-desorption, XRD, SEM-EDS, TEM, NH₃-TPD, XPS, H₂-TPR and Raman. The results show that specific surface area and pore volume of as-prepared catalysts decrease to some extent with the increasing addition of CaO. However, the proper amounts of CaO (≤3 wt%) significantly enhance the catalytic activity in terms of n-decane conversion and H₂ selectivity mainly due to the improved dispersion of NiO particles (precursor of Ni particles). As for anti-coking performance, reducibility of CeO₂ in composite oxide support CZA is promoted by CaO resulting in providing more lattice oxygen, which favors suppressing coke formation. Moreover, the addition of CaO reduces the acidity of 10%Ni/CZA, especially the medium and strong acidity. But far more importantly, a better dispersion of NiO particles obtained by proper amounts of CaO addition is dominant for the lower carbon formation, as well as the higher catalytic activity. For the spent catalysts, amorphous carbon is the main type of coke over 10%Ni–3%CaO/CZA, while abundant filamentous carbon is found over the others.     

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.     

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.     

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.     

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.     

Bifunctional Ni–CaO catalysts modified with CeO2 and inert Ca12Al14O33 for sorption-enhanced steam reforming of ethanol

In this work, sorption-enhanced steam reforming of ethanol (SE-SRE) process was studied using Ni–CaO-based bifunctional catalysts modified with Ca₁₂Al₁₄O₃₃ (mayenite) and CeO₂. The CaO and CaO/Ca₁₂Al₁₄O₃₃ sorbents were synthesized by a sol-gel method and, subsequently, CeO₂ and Ni were added by the incipient wetness impregnation method. These materials were characterized by BET surface area, thermogravimetric analysis (TGA), in situ X-ray diffraction (XRD), and in situ X-ray absorption near edge structuare (XANES). In addition, the catalysts were tested on 10 cycles of SE-SRE reaction and regeneration. In general, the characterization results revealed an inverse relationship between average crystallite size of CaO and CO₂ sorption capacity. By the in situ XRD/XANES, the addition of the mayenite reduced by half the average crystallite size of CaO and increased the interaction between support and active phase. As a consequence, the catalyst containing mayenite (NiCaAl) showed the best CO₂ capture uptake and stability, which could be justified mitigation of the CaO sintering effect by the inert material presence. Great stability was also observed in the catalytic tests, since the duration of the pre-breakthrough stage for NiCaAl and for the catalyst containing maynite and ceria (NiCaAlCe) remained constant over the reaction cycles. In terms of hydrogen production, NiCaAl catalyst showed the highest H₂ molar fraction during the pre- (90%) and post-breakthrough. The CeO₂ addition slightly favored the methane formation, although did not bring significant benefits in the CO₂ capture and catalytic performance. Therefore, NiCaAl showed the best CO₂ capture capacity and stability, which led to the best SE-SRE performance.     

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.     

Influence of metal-support interactions on reaction pathways over Ni/CeZrOx–Al2O3 catalysts for ethanol steam reforming

This work investigates selective Ni locations over Ni/CeZrO_x–Al₂O₃ catalysts at different Ni loading contents and their influences on reaction pathways in ethanol steam reforming (ESR). Depending on the Ni loading contents, the added Ni selectively interacts with CeZrO_x–Al₂O₃, resulting in the stepwise locations of Ni over CeZrO_x–Al₂O₃. This behavior induces a remarkable difference in hydrogen production and coke formation in ESR. The selective interaction between Ni and CeZrO_x for 10-wt.% Ni generates more oxygen vacancies in the CeZrO_x lattice. The Ni sites near the oxygen vacancies enhance reforming via steam activation, resulting in the highest hydrogen production rate of 1863.0 μmol/g_cat·min. In contrast, for 15 and 20-wt.% Ni, excessive Ni is additionally deposited on Al₂O₃ after the saturation of Ni–CeZrO_x interactions. These Ni sites on Al₂O₃ accelerate coking from the ethylene produced on the acidic sites, resulting in a high coke amount of 19.1 mg_c/g_cat·h (20Ni/CZ-Al).     

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.     

Characterization and catalytic behavior of hydrotalcite-derived Ni–Al catalysts for methane decomposition

A series of Ni catalysts were prepared from Ni–Al hydrotalcite-like compounds (HTlcs) by varying the Ni/Al molar ratio (1–4) and calcination temperature (773–1173 K) of HTlcs. The catalysts were reduced with H₂ at 1073 K and tested for CH₄ decomposition at 773–923 K on a thermal gravimeter. Various techniques including N₂ physical adsorption, XRD, H₂-TPR, XPS, HAADF-STEM, TEM, and Raman were applied to characterize the catalysts and the as-produced carbon. The characterizations show that calcination of Ni–Al HTlcs leads to Ni(Al)O solid solution and minor NiO and/or NiAl₂O₄ spinel may be formed depending on the Ni/Al ratio and calcination temperature; upon reduction at 1073 K, most nickel species are reduced to metallic Ni. In CH₄ decomposition, carbon yield shows a volcano-type dependence on the Ni content with the optimum Ni/Al ratio equal to 3. On the other hand, carbon yield is affected by the calcination temperature of the Ni₃Al HTlcs to a small extent. Carbon yield is also significantly affected by the reaction temperature, which decreases remarkably with a rise of temperature to 923 K. TEM and Raman indicate that fish-bone carbon nanofibers are formed at 773–823 K, whereas multi-walled carbon nanotubes are formed at 873–923 K.     

Impacts of nickel loading on properties,catalytic behaviors of Ni/γ–Al2O3 catalysts and the reaction intermediates formed in methanation of CO2

In this study, methanation of CO₂ over Ni/Al₂O₃ with varied nickel loading (from 0 to 50 wt%) was evaluated, striving to explore the effects of nickel loading on catalytic behaviors and the reaction intermediates formed. The results showed that agglomeration of nickel particles were closely related to interaction between nickel and alumina. Increasing nickel loading resulted in the increased proportion of nickel having medium strong interaction with alumina, the reduced reduction degree of NiO, the increase of medium to strong basic sites, the enhanced activity for methanation and the competition between reverse water gas shift (RWGS) reaction and methanation. Lower nickel loading promoted RWGS reaction while methanation of CO₂ dominated at higher nickel loading. The catalyst with a nickel loading around 25% achieved the best activity for methanation. The in–situ DRIFTS studies of methanation of CO₂ showed that CO₂ could be absorbed on surface of metallic Ni, NiO or alumina. More metallic nickel species on alumina suppressed formation of carbonate species while promoted further conversion of HCOO¹ species and ¹CH₃ species, achieving a higher catalytic efficiency. Moreover, more metallic nickel species was crucial for gasifying the carbonaceous intermediates, prevented aggregation of the intermediates to coke and achieving a higher catalytic stability.     

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.     

Effect of La2O3 replacement on γ-Al2O3 supported nickel catalysts for acetic acid steam reforming

The effect of replacement of γ-Al₂O₃ by La₂O₃ was studied on Ni catalysts for hydrogen production via acetic acid steam reforming. The La/(La + Al) weight ratio ranged from 0 to 1 in the catalyst support prepared by co-precipitation method. Over the Ni/La-3Al catalyst (the La/(La + Al) weight ratio at 0.25), the carbon conversion and hydrogen yield reached 100% and 72.72%, respectively, which was obviously higher than other catalysts at 700 °C, S/C = 1 and LHSV = 10 h^?1. The effect of S/C, LHSV and stability test were studied in detail over Ni/La-3Al catalyst, whose high activity maintained for more than 30 h.     

Mixed reforming of methane over Ni–K/CeO2–Al2O3: Study of catalyst performance and reaction kinetics

Syngas can be effectively produced by mixed reforming of methane (MRM). In this work, the performance of Ni–K/CeO₂–Al₂O₃ catalyst in this process was investigated in a fixed-bed reactor in the 923–1073 K range. Both potassium and ceria are renowned for improving the performance of Ni catalyst in the reforming process. The influence of reaction conditions (viz. temperature, space time, feed composition and time-on-stream) on the conversion of two reactants CH₄ and CO₂, yield of the products H₂ and CO and the H₂/CO ratio in syngas were studied. At T = 1073 K and W/Q₀ = 0.17 g-h/L (here, W and Q₀ denote catalyst mass and volumetric flow rate of feed), conversions of CH₄ and CO₂ were 91.2 and 80.1%. When S/C ratio (or steam-to-carbon ratio) in feed increased from 0.2 to 0.5 mol/mol, H₂/CO ratio at T = 1073 K changed from 1.32 to 2.14 mol/mol. The catalyst performed stably for 50 h of time-on-stream. Reaction kinetics was studied between 973 and 1073 K and power law kinetic model was suggested. The apparent activation energy values for consumption of CH₄ and CO₂ were found to be 33.3 and 45.5 kJ/mol, respectively. This work is expected to aid catalyst development and reactor design for the MRM process.     

High performance of Mg–La mixed oxides supported Ni catalysts for dry reforming of methane: The effect of crystal structure

A series of mixed Mg–La oxide supports with various Mg²⁺/La³⁺ mole ratios were prepared via co-precipitation of Mg and La nitrates, and then impregnated to form 5 wt.% Ni catalysts. The as-prepared catalysts were evaluated in DRM reaction for 200 h and characterized by means of in situ DRIFTS, XRD, TEM, CO₂-TPD, XPS, and TGA. It was found that the interaction of suitable amount of MgO with La₂O₃ stabilized cubic La₂O₃ species in catalysts, which has high basicity to adsorb CO₂ forming monoclinic La₂O₂CO₃ (Ia) species in DRM reaction. The introduction of MgO also created surface oxygen ions (i.e. O^–). Both monoclinic La₂O₂CO₃ (Ia) and surface oxygen species are able to oxidize and remove deposited carbon, keeping the Ni catalyst at high activity and stability. Low Mg²⁺/La³⁺ ratios generated hexagonal La₂O₃ and La₂O₂CO₃ (II) in DRM reaction. The hexagonal La₂O₂CO₃ (II) did not play significant role in carbon removal so that the catalysts deactivated fast.