A review on bi/polymetallic catalysts for steam methane reforming

Blue hydrogen production by steam methane reforming (SMR) with carbon capture is by far the most commercialised production method, and with the addition of a simultaneous in-situ CO₂ adsorption process, sorption-enhanced steam methane reforming (SESMR) can further decrease the cost of H₂ production. Ni-based catalysts have been extensively used for SMR because of their excellent activity and relatively low price, but carbon deposition, sulphation, and sintering can lead to catalyst deactivation. One effective solution is to introduce additional metal element(s) to improve the overall performance. This review summarizes recent developments on bi/polymetallic catalysts for SMR, including promoted nickel-based catalysts and other transition metal-based bi/polymetallic materials. The review mainly focuses on experimental studies, but also includes results from simulations to evaluate the synergistic effects of selected metals from an atomic point of view. An outlook is provided for the future development of bi/polymetallic SMR catalysts.     

System optimization for effective hydrogen production via anaerobic digestion and biogas steam reforming

To construct a system for the effective hydrogen production from food waste, the conditions of anaerobic digestion and biogas reforming have been investigated and optimized. The type of agitator and reactor shape affect the performance of anaerobic digestion reactors. Reactors with a cubical shape and hydrofoil agitator exhibit high performance due to the enhanced axial flow and turbulence as confirmed by simulation of computational fluid dynamics. The stability of an optimized anaerobic digestion reactor has been tested for 60 days. As a result, 84 L of biogas is produced from 1 kg of food waste. Reaction conditions, such as reaction temperature and steam/methane ratio, affect the biogas steam reforming reaction. The reactant conversions, product yields, and hydrogen production are influenced by reaction conditions. The optimized reaction conditions include a reaction temperature of 700 °C and H₂O/CH₄ ratio of 1.0. Under these conditions, hydrogen can be produced via steam reforming of biogas generated from a two-stage anaerobic digestion reactor for 25 h without significant deactivation and fluctuation.     

A review on recent advances in dry reforming of methane over Ni- and Co-based nanocatalysts

The recent environmental-related issues such as climate change and global warming have sparked scientists' interest in finding a way to reduce the emission of greenhouse gases through dry reforming of CH₄. As a result of this reaction, not only H₂ is produced, but also CO₂ and CH₄ are reduced. Catalysts are needed due to the enhancement of the kinetics of the reaction. Non-noble metals like Ni, Co, etc., have shown promising activity, they are readily available, and have low cost; consequently, they have been widely employed for the reaction. In this paper, the recent advances in the development of the Ni- and Co-based nanocatalysts for DRM reaction, including the use of different supports and promoters, the addition of alkaline earth metals, and new structures like mesoporous silica and dendritic fibrous nano silica as supports were reviewed.     

Enhancing resistance of carbon deposition and reaction stability over nickel loaded fibrous silica-alumina (Ni/FSA) for dry reforming of methane

Syngas production from the dry reforming of methane is now the most extensively utilized method for removing massive amounts of greenhouse emissions. Effective solutions towards the utilization of greenhouse gases such as CO₂ and CH₄ are scarce, except for power generation in the energy sector, which is a major source of CO₂. Herein, dry reforming of methane was experimented for the first time using an effective catalytic system composed of 5% Ni fibrous silica-alumina (FSA) that was successfully fabricated using a hydrothermal method. The characterization results from XRD, FESEM mapping, TEM, BET,XRF, FTIR, H₂-TPR, TGA/DTA, and Raman spectra demonstrated that Ni/FSA is composed of orderly Ni dispersion, small particles of Ni, robust basic sites, and high oxygen vacancies which enhanced the catalytic efficiency. The synthesized Ni/FSA also reduced coke formation and had long-term stability with no evidence of inactivation during and after the catalytic cycles. The superior activity of Ni/FSA was manifested in the high conversion rates of CH₄ and CO₂ at 97% and 92% respectively, with a H₂:CO ratio of ≈ 1. The stability of Ni/FSA was also sustained over 30 h of operation at 800 °C. The findings of the Raman, TEM, and TGA/DTA tests revealed that the spent Ni/FSA catalysts did not exhibit graphitic carbon or metal sintering in significant amounts when compared to commercial Ni–Si/Al catalysts.     

Simulation and optimization of hydrogen production by steam reforming of natural gas for refining and petrochemical demands in Lebanon

Steam reforming of natural gas produces the majority of the world's hydrogen (H₂) and it is considered as a cost-effective method from a product yield and energy consumption point of view. In this work, we present a simulation and an optimization study of an industrial natural gas steam reforming process by using Aspen HYSYS and MATLAB software. All the parameters were optimized to successfully run a complete process including the hydrogen production zone units (reformer reactor, high temperature gas shift reactor HTS and low temperature gas shift reactor LTS) and the purification zone units (absorber and methanator). Optimum production of hydrogen (87,404 MT/year) was obtained by fixing the temperatures in the reformer and the gas shift reactors (HTS & LTS) at 900 °C, 500 °C and 200 °C respectively while maintaining a pressure of 7 atm, and a steam to carbon ratio (S/C) of 4. Moreover, ~99% of the undesired CO₂ and CO gases were removed in the purification zone and a reduction of energy consumption of 77.5% was reached in the heating and cooling units of the process.     

Variations of methane conversion process with the geometrical effect in rotating gliding arc reactor

Controllability of the kinetic path of methane conversion in plasma driven oxidation reaction is investigated. Different geometries in a rotating gliding arc reactor are adopted to control reaction paths in methane oxidation reaction. Diverging and converging type reactor product different reaction environments in view point of both the reaction time and the degree of thermal activation. In the diverging reactor, the partial oxidation process is dominant with high methane conversion because the diverging section facilitates to elongate the arc length and decrease the flow velocity. Thus, the convective and radiative heat transfer from the arc column to the reactants could be enhanced. The role of plasma in the diverging reactor is mainly igniting and sustaining the partial oxidation, which is rather different from that in the converging reactor where the plasma plays as a heat source for thermal pyrolysis of methane with the help of focusing thermal energy of the arc.     

Catalyst modification strategies to enhance the catalyst activity and stability during steam reforming of acetic acid for hydrogen production

A high energy content (∼122 MJ/kg H₂) and presence of hydrogen-bearing compounds abundance in nature make hydrogen forth runner candidate to fulfill future energy requirements. Biomass being abundant and carbon neutral is one of the promising source of hydrogen production. In addition, it also addresses agricultural waste disposal problems and will bring down our dependency on fossil fuel for energy requirements. Biomass-derived bio-oil can be an efficient way for hydrogen production. Acetic acid is the major component of bio-oil and has been extensively studied by the researchers round the globe as a test component of bio-oil for hydrogen generation. Hydrogen can be generated from acetic acid via catalytic steam reforming process which is thermodynamically feasible. A number of nickel-based catalysts have been reported. However, the coke deposition during reforming remains a major challenge. In this review, we have investigated all possible reactions during acetic acid steam reforming (AASR), which can cause coke deposition over the catalyst surface. Different operating parameters such as temperature and steam to carbon feed ratio affect not only the product distribution but also the carbon formation during the reaction. Present review elaborates effects of preparation methods, active metal catalyst including bimetallic catalysts, type of support and microstructure of catalysts on coke resistance behavior and catalyst stability during reforming reactions. The present study also focuses on the effects of a combination of a variety of alkali and alkaline earth metals (AAEM) promoters on coke deposition. Effect of specially designed reactors and the addition of oxygen on carbon deposition during AASR have also been analyzed. This review based on the available literature focuses mainly on the catalyst deactivation because of coke deposition, and possible strategies to minimize catalyst deactivation during AASR.     

Semi-analytical modeling of productivity analysis for five-spot well pattern scheme in methane hydrocarbon reservoirs

Five-spot well pattern (FSWP) scheme has shown appealing potentialities to enhance the recovery of coal-bed methane (CBM) from methane hydrocarbon reservoirs (MHR). In this paper, a new framework aimed at systematically investigating productivity performance of FSWP scheme with inter-well pressure interference (IWPI) is presented. First, mathematical models which are used to characterize the fluid flow within MHR and hydraulic fractures (HFs) are separately derived. Second, Laplace transformation and Stehfest numerical algorithm are utilized to couple those two flow systems and obtain the pressure-transient solutions of FSWP scheme. Finally, pressure characteristics are discerned and sensitivity analysis of key parameters is implemented as well. This semi-analytical approach outperforms numerical simulation from the point of computational efficiency. Several common flow regimes, e.g., linear and bi-linear flow regimes, are essentially deformed induced by IWPI. Several significant parameters, including gas rate, fracture half-length, and well spacing on the occurrence of IWPI are systematically analyzed. This work gains some new knowledge about the productivity performance of FSWP scheme with the existence of IWPI when extracting CBM from methane hydrate reservoirs (MHR), which provides energy engineers considerable instructions on optimizing the development of methane hydrate reservoirs.     

Utilization of laterite ore as an oxygen carrier in chemical looping reforming of methane for syngas production

Growing energy demands in various sectors have resulted in overusing fossil fuel sources and rise in greenhouse gases in the atmosphere. This necessitates the need for reducing greenhouse gases and shifting to cleaner, renewable energy sources like H₂. Chemical looping is one such renewable method to produce clean H₂. The efficiency of this process depends on the oxygen carrier. Generally, oxygen carriers (OC) are transition metal oxides (Fe₂O₃ or NiO) or some complex metal oxides like spinel or perovskites, but usage of these OCs are restricted due to their availability and redox performance. One solution for selecting OCs can be using industrial waste like slag or low-grade ores because of their composition, which consists of metal oxides. One such low-grade ore is Ni-laterite ore or chromite overburden, a mining waste found in the chromite mines of Sukinda (India). In this work, we have focused on utilizing this laterite ore as an OC for the chemical looping reforming of methane to produce syngas. The reactivity analysis of laterite ore with CH₄ was performed in DSC-TG and the reaction products were analyzed in gas chromatography along with microscopy and spectroscopic techniques. Results showed the formation of H₂ and CO gases along with reduced metallic phases. The total H₂ yield at 750 °C is determined to 53.67 (±1.09) ml/g of OC which is comparable or even higher than existing CeO₂ based OCs. Further, thermodynamic calculations are presented to calculate the theoretical yield for our process and compared with the experimental H₂ yield. This study effectively demonstrates the performance of laterite ore as an OC for generating clean and renewable energy through chemical looping technique.     

Steam reforming of 1-methylnaphthalene over pure CeO2 under model coke oven gas conditions containing high H2S concentrations

Tar and H₂S are obstacles to the efficient production of H₂ from unused industrial gases and biomass gasification gases. Robust catalysts against tar and H₂S are required to produce H₂ from such resources. Herein, a stable steam reforming reaction is demonstrated over pure CeO₂ under reaction conditions consisting of ~2 vol% 1-methylnaphthalene and ~1000 ppm H₂S. The presence of H₂S significantly suppressed Ni/MgO/Al₂O₃ activity and increased carbon deposition, regardless of the steam to carbon (S/C) ratio. In contrast, the promotion or suppression of CeO₂ activity in the presence of H₂S was dependent on the S/C ratio. At S/C = 1.2, H₂S deactivated the CeO₂ catalyst and increased carbon deposition. Conversely, H₂S promoted the reforming reaction and decreased carbon deposition on CeO₂ at S/C ≥ 2.0. The results of this study clarify that pure CeO₂ exhibits outstanding and stable activity for the steam reforming reaction of 1-methylnaphthalene in the presence of H₂S by controlling the S/C of the inlet gas.     

Preparation and improvement of nickel catalyst supported ordered mesoporous spherical silica for thermocatalytic decomposition of methane

The thermocatalytic alteration of CH₄ into highly pure hydrogen and filaments of carbon was investigated on a series of Ni-catalysts with various contents (25, 40, 55, and 70 wt%) supported mesoporous spherical SiO₂. The silica with ordered structure and high specific surface area (1136 m²/g) was synthesized using the Stöber technique with TEOS as a silica precursor and CTAB as the template in a simple synthesis system of aqueous-phase. This technique led to the preparation of mesoporous spherical silica. The prepared samples were characterized using BET, TPR, XRD, TPO, and SEM analyses. The prepared catalysts with different nickel loading showed the BET surface area ranging from 225.0 to 725.7 m²/g. These results indicated that an increase in nickel content decreases the surface area and leads to a subsequent collapse of a pore structure. SEM analysis confirmed a spherical nanostructure of catalysts and revealed that with the increase in loading of Ni, the particle size enlarged, because of the agglomeration of the particles. The results implied that the high methane conversion of 54% obtained over the 55 wt% Ni/SiO₂ at 575 °C and this sample had higher stability at lower reaction temperature than the other prepared catalysts, slowly deactivation was observed for this catalyst at a period of 300 min of time on stream.     

Hydrogen sulphide to hydrogen via H2S methane reformation: Thermodynamics and process scheme assessment

Hydrogen Sulphide Methane Reformation (HSMR) represents a valid alternative for the simultaneous H₂S valorisation and hydrogen production at the industrial scale, without direct CO₂ emissions. The major concerns about the process commercialization are the possible coke formation in the reaction zone and the lack of active and selective catalysts. The study of the thermodynamics is the essential preliminary step for the reaction phenomena understanding. In this work, a deep thermodynamic analysis is performed to explore the system behaviour as a function of temperature, pressure, and inlet feed composition, using the Aspen Plus RGibbs module. In this way, the optimal process operating conditions to avoid carbon lay down can be identified.Assessed the system's thermodynamics, a preliminary process scheme is developed and simulated in Aspen Plus V11.0®, considering hydrogen production and its distribution in pipeline with methane. The process performances are discussed in terms of products' purity and process energy consumptions.     

Producing hydrogen from the fermentation of cheese whey and glycerol as cosubstrates in an anaerobic fluidized bed reactor

This study aimed to evaluate the effect of the organic loading rate (OLR) (60, 90, and 120 g Chemical Oxygen Demand (COD). L^?1. d^?1) on hydrogen production from cheese whey and glycerol fermentation as cosubstrates (50% cheese whey and 50% glycerol on a COD basis) in a thermophilic fluidized bed reactor (55 °C). The increase in the OLR to 90 gCOD.L^?1. d^?1 favored the hydrogen production rate (HPR) (3.9 L H₂. L^?1. d^?1) and hydrogen yield (HY) (1.7 mmol H₂. gCOD^?1_app) concomitant with the production of butyric and acetic acids. Employing 16S rRNA gene sequencing, the highest hydrogen production was related to the detection of Thermoanaerobacterium (34.9%), Pseudomonas (14.5%), and Clostridium (4.7%). Conversely, at 120 gCOD.L^?1. d^?1, HPR and HY decreased to 2.5 L H₂. L^?1. d^?1 and 0.8 mmol H₂. gCOD^?1_app, respectively, due to lactic acid production that was related to the genera Thermoanaerobacterium (50.91%) and Tumebacillus (23.56%). Cofermentation favored hydrogen production at higher OLRs than cheese whey single fermentation.     

Nickel-loaded red mud catalyst for steam gasification of bamboo sawdust to produce hydrogen-rich syngas

Ni/red mud (RM) catalysts were prepared by wet impregnation and used in the catalytic steam gasification of bamboo sawdust (BS) to produce hydrogen-rich syngas. The system was optimized in terms of the amount of added nickel (10%), reaction temperature (800 °C), and catalyst placement (separately behind the BS). The maximum H₂ yield was 17.3% higher than that using pure RM catalyst and 43.8% higher than that of BS gasification alone, and the H₂/CO ratio in the syngas reached 7.82. This Ni/RM catalyst also retained good activity after six cycles in a double-stage fixed bed reactor. Analysis using X-ray fluorescence, X-ray diffraction, scanning electron microscopy-energy dispersive spectroscopy, and other methods revealed that the interaction of Ni, Fe, and Mg in Ni/RM produced bimetallic compounds containing active sites, such as NiFe₂O₄, MgNiO₂, and NiO. This explains the good catalytic performance in the tar conversion during the gasification process.     

A strategy of mid-temperature natural gas based chemical looping reforming for hydrogen production

Steam methane reforming (SMR) needs the reaction heat at a temperature above 800 °C provided by the combustion of natural gas and suffers from adverse environmental impact and the hydrogen separated from other chemicals needs extra energy penalty. In order to avoid the expensive cost and high power consumption caused by capturing CO₂ after combustion in SMR, natural gas Chemical Looping Reforming (CLR) is proposed, where the chemical looping combustion of metal oxides replaced the direct combustion of NG to convert natural gas to hydrogen and carbon dioxide. Although CO₂ can be separated with less energy penalty when combustion, CLR still require higher temperature heat for the hydrogen production and cause the poor sintering of oxygen carriers (OC). Here, we report a high-rate hydrogen production and low-energy penalty of strategy by natural gas chemical-looping process with both metallic oxide reduction and metal oxidation coupled with steam. Fe₃O₄ is employed as an oxygen carrier. Different from the common chemical looping reforming, the double side reactions of both the reduction and oxidization enable to provide the hydrogen in the range of 500–600 °C under the atmospheric pressure. Furthermore, the CO₂ is absorbed and captured with reduction reaction simultaneously.Through the thermodynamic analysis and irreversibility analysis of hydrogen production by natural gas via chemical looping reforming at atmospheric pressure, we provide a possibility of hydrogen production from methane at moderate temperature. The reported results in this paper should be viewed as optimistic due to several idealized assumptions: Considering that the chemical looping reaction is carried out at the equilibrium temperature of 500 °C, and complete CO₂ capture can be achieved. It is assumed that the unreacted methane and hydrogen are completely separated by physical adsorption. This paper may have the potential of saving the natural gas consumption required to produce 1 m³ H₂ and reducing the cost of hydrogen production.     

Enhanced methane production using pretreated sludge in MEC-AD system: Performance,microbial activity,and implications at different applied voltages

Although various pretreatment methods are employed to promote sludge hydrolysis and thereby promoting methane production in the subsequent microbial electrolysis cell assisted anaerobic digestion (MEC-AD) system, the questions arise are, “which pretreatment method on waste activated sludge (WAS) maximises the sludge hydrolysis and what is the optimal applied voltage on anaerobic digestion (AD) to stimulates the direct interspecies electron transfer (DIET) performance and thereby accelerating the methane production fed with pretreated WAS?” was still unanswered. Herein, firstly, a series of pretreatment methods to hydrolyse and mineralise the organic matter of WAS was performed to evaluate solubilization efficiency and thereafter, the influence of different applied voltages (0.3 V, 0.6 V, and 0.9 V) on coupled MEC-AD reactors fed with pretreated WAS was investigated to apprehend the DIET promotion for methane production. The results indicated that in MEC-AD reactors, the methane yield increased by 27.2%, 44.8%, and 37.3% when the applied voltages were 0.3 V, 0.6 V, and 0.9 V, respectively. Therefore, the alkaline-thermal pretreatment (ATP) enhanced the sludge hydrolysis in WAS, followed by an applied voltage of 0.6 V in the MEC-AD reactor fed with pretreated WAS, enhanced methane production under DIET stimulation induced by the increased abundance of electroactive microorganisms (EAM) and the advanced electron transfer. Besides, the energy balance estimation validates that with an applied voltage of 0.6 V in MEC-AD could achieve higher net energy input.     

An autonomous fuel cell: Methanol and dimethyl ether steam reforming direct fed to fuel cell

Studies of reforming systems integrated with Fuel Cells are interesting for energy production in remote regions, especially to develop multi-fuel processors, which can be fed by more than one fuel with no need to modify the unit. In this work, an Autonomous Fuel Cell (AFC) system with methanol and/or Dimethyl Ether Steam Reforming (SR) was modeled and simulated in Aspen Plus, evaluating process variables, appropriate operational conditions, and the need for additional processes. The maximum hydrogen formed is H₂/C = 3.0 (yield of 99.9%) and occurs generally with S/C ≥ 2 for several temperatures. The presence of a WGS reactor and a membrane for hydrogen purification was identified as vital to develop an AFC. In six situations that were studied with different operating conditions that meet the AFC operation, it was observed that the lowest temperature is preferable since it will consume the least amount of utility to maintain the SR.     

Improvement of biohydrogen production from brewery wastewater: Evaluation of inocula,support and reactor

This work explores the production of biohydrogen from brewery wastewater using as inoculum a culture produced by natural fermentation of synthetic wastewater and Klebsiella pneumoniae isolated from the environment. Klebsiella pneumoniae showed good performance as inoculum, as evaluated using assays of between 9 and 16 cycles, with durations of 12 and 24 h, carbohydrate concentrations from 2.79 to 7.22 g L⁻¹, and applied volumetric organic loads from 2.6 to 12.6 g carbohydrate L⁻¹ day⁻¹. The best results were achieved with applied volumetric organic loads of 12.6 g carbohydrate L⁻¹ day⁻¹ and cycle length of 12 h, resulting in mean volumetric productivity of 0.88 L H₂ L⁻¹ day⁻¹, maximum molar flow of 10.80 mmol H₂ h⁻¹, and mean yield of 0.70 mol H₂ mol⁻¹ glucose consumed. The biogas H₂ content was between 18 and 42%, while the mean organic compounds removal and carbohydrate conversion efficiencies were 23 and 81%, respectively. The inoculum produced by natural fermentation was not viable.     

Production of syngas from steam gasification of three different ranks of coals and related reaction kinetics

The steam gasification properties of three different ranks of coals, Shengli lignite (SL), Shenhua subbituminous coal (SH), and Tavan Tolgoi anthracite (TT), were investigated using a lab-scale fixed-bed reactor, and the thermodynamic equilibrium constant and kinetics of the reaction were analyzed. The results showed that the aromaticity and condensation of aromatic structures in SL, SH, and TT became higher, and the maturity of organic substance became lower. The steam gasification reaction showed that the syngas from low-rank SL had a high H₂/CO molar ratio, while the syngas from high-rank TT had relatively high CO content. The direct carbon gasification reactions for these three different ranks of coals were far from in equilibrium; the water gas shift reaction of SL was near equilibrium, and the degree of reaction for SL was higher than that of SH and TT. We studied a random pore model (RPM), shrinking core model (SCM), and hybrid model (HM), and the hybrid model was found to be the most suitable model of the three for fitting the steam gasification reactions of the three types of coal. It had high fitting correlation coefficient R² values (ranging from 0.9939 to 0.9990) and small average error θ values (ranging from 0.009 to 0.016). The apparent activation energy E values of SL, SH, and TT fitted by HM were 179.10, 48.14, and 63.06 kJ/mol, respectively, and the corresponding pre-exponential factor k₀ values were 3.14 × 10⁷, 1.01, and 1.22 min⁻¹, respectively. This study finds that the steam gasification of SL, SH, and TT coal samples consists of homogeneous phase reaction and shrinking core reaction.     

Study of thrust vector control for the rotating detonation model engine

The detonation wave in a rotating detonation engine is highly adaptable to the incoming flow, making the wave easier to control. In this study, a numerical simulation method is used to analyze the working process and flow field structure of a rotating detonation model engine with dual cavity injection of an H₂/air mixture by controlling the injection pressure ratio of the dual cavity and the number of detonation wave heads. It is found that the rotating detonation engine offers the possibility to control the thrust vector with two different modes. The first is a one-cycle alternate control mode with a small injection pressure ratio. Here two deflections occur in different directions occur across one detonation wave propagation cycle, but the overall deflection direction is in the low-pressure region. The second is a one-way control mode, with a large injection pressure ratio, and the deflection direction towards the low-pressure region. For the multi wave-mode, it belongs to one-way control mode because of constant deflection direction in the low-pressure area. From the perspective of thrust distribution along the circumference, the one-way control strategy satisfies the ability of a rotating detonation thrust vector control.