A comparative study on the performance of mesoporous SBA-15 supported Pd–Zn catalysts in partial oxidation and steam reforming of methanol for hydrogen production

Using mesoporous SBA-15 (Santa Barbara Amorphous No. 15, a mesoporous material) as support, Pd–Zn nanocatalysts with varying Pd and Zn content were tested for hydrogen production from methanol by partial oxidation and steam reforming reactions. The physico-chemical characteristics of the synthesized SBA-15 support were confirmed by XRD, N₂ adsorption, SEM and TEM analyses. The PdZn alloy formation during the reduction of Pd–Zn/SBA-15 was revealed by XRD and DRIFT study of adsorbed CO. Also, the correlation between Pd and Zn loadings and PdZn alloy formation was studied by XRD and TPR analyses. The metallic Pd surface area and total uptakes of CO and H₂ were measured by chemisorption at 35 °C. The metallic Pd surface area values are in linear proportion with the Pd loading. The formation of PdZn alloy during high temperature reduction was confirmed by a shift in absorption frequency of CO on Pd sites to lower frequency due to higher electron density at metal particles resulted from back-donation. The reduced Pd–Zn/SBA-15 catalysts were tested for partial oxidation of methanol at different temperatures and found that catalyst with 4.5 wt% Pd and 6.75 wt% Zn on SBA-15 showed better H₂ selectivity with suppressed CO formation due to the enhanced Pd dispersion as well as larger Pd metallic surface area. The O₂/CH₃OH ratio is found to play a significant role in CH₃OH conversion and H₂ selectivity. The performance of 4.5 wt% Pd–6.75 wt% Zn/SBA-15 catalyst in steam reforming of methanol was also tested. Comparatively, the H₂ selectivity is significantly higher than that in partial oxidation, even though the CH₃OH conversion is less. Finally, the long term stability of the catalyst was tested and the nature of PdZn alloy after the reactions was found to be stable as revealed from the XRD pattern of the spent catalysts.     

Catalytic steam reforming of methanol over highly active catalysts derived from PdZnAl-type hydrotalcite on mesoporous silica MCM-48

A kind of composite material PdZnAl(HT)/MCM-48 was synthesized by dispersing PdZnAl-type hydrotalcite (denoted as PdZnAl(HT)) on mesoporous silica MCM-48. PdZnAl(HT) was confirmed to be formed on the MCM-48 in small particles, and the small PdZnAl(HT) particles easily collapsed during increasing the temperature. A kind of novel PdZn(Al)O/MCM-48 catalyst was obtained after calcining and reducing the PdZnAl(HT)/MCM-48 precursor. PdZn alloy species were formed on the PdZnAl(HT)/MCM-48 after reducing in H₂ at 673 K. PdZn(Al)O/MCM-48-2 (with a mass ratio of PdZn(Al)O to MCM-48 = 1) had a large BET surface area (431 cm² g^?1) and small size of PdZn particles (4.1 nm) at the same time. In the steam reforming of methanol, the catalytic stability of PdZn(Al)O/MCM-48-2 was much higher than that of the Cu-based catalyst CuZn(Al)O at 503 K. The methanol conversion over PdZn(Al)O/MCM-48-2 greatly increased with increasing reaction temperature and reached 99% at 513 K. PdZn(Al)O/MCM-48-2 showed higher catalytic activity than PdZnAl(HT) and PdZn/MCM-48 (imp) at the same reaction temperature. The initial CO₂ selectivity and H₂ selectivity over PdZn(Al)O/MCM-48-2 at 503 K were 99.6 and 99.4%, respectively. Moreover, PdZn(Al)O/MCM-48-2 showed the highest rate of H₂ production among various catalysts in the steam reforming of methanol. In a long-time operation, the methanol conversion over PdZn(Al)O/MCM-48-2 decreased from 75.8 to 68.5% after 50 h on stream at 503 K. The size of PdZn particles did not increase after 50 h on stream but the carbonaceous deposits on the catalyst surface caused the deactivation. The deactivated catalyst could be regenerated by calcining in the air at 723 K followed by reducing in the H₂ at 673 K. The carbonaceous deposits were eliminated by calcining in the air and the PdZn active species were formed again by reducing in H₂.     

Zinc oxide nanorods based catalysts for hydrogen production by steam reforming of methanol

Zinc oxide (ZnO) nanorods were epitaxially grown on porous cordierite support by a hydrothermal process and utilized for catalyzing methanol steam reforming (MSR) reaction. Catalytic activity of ZnO nanorods for MSR process was correlated to the terminated surfaces of ZnO crystallites. Copper (Cu), palladium (Pd) and gold (Au) nanoparticles infused ZnO nanorods were prepared by in-situ precipitation of the metals on the nanorods. 28% hydrogen selectivity was observed with Cu/ZnO nanorods (Cu/10Zn), while Pd/ZnO nanorods and (Pd/10Zn) showed slightly lower activity. Higher catalytic activity of copper and palladium impregnated ZnO nanorods can be attributed to the synergistic combination of bimetallic oxides. In contrast, Au/ZnO nanorods (Au/10Zn) showed very high activity for methanol dehydrogenation and higher than 97% methanol conversion was achieved for operating temperatures as low as 200 °C.     

Synergetic integration of a methanol steam reforming cell with a high temperature polymer electrolyte fuel cell

In this work an integrated unit, combining a methanol steam-reforming cell (MSR-C) and a high temperature polymer electrolyte membrane fuel cell (HT-PEMFC) was operated at the same temperature (453 K, 463 K and 473 K) allowing thermal integration and increasing the system efficiency of the combined system. A novel bipolar plate made of aluminium gold plated was built, featuring the fuel cell anode flow field in one side and the reformer flow field on the other. The combined unit (MSR-C/HT-PEMFC) was assembled using Celtec^® P2200N MEAs and commercial reforming catalyst CuO/ZnO/Al₂O₃ (BASF RP60). The water/methanol vaporisation originates oscillations in the vapour flowrate; reducing these oscillations increase the methanol conversion from 93% to 96%. The MSR-C/HT-PEMFC showed a remarkable high performance at 453 K. The integrated unit was operated during ca. 700 h at constant at 0.2 A cm^?2, fed alternately with hydrogen and reformate at 453 K and 463 K. Despite the high operating temperature, the HT-PEMFC showed a good stability, with an electric potential difference decreasing rate at 453 K of ca. 100 μV h^?1. Electrochemical impedance spectroscopy (EIS) analysis revealed an overall increase of the ohmic resistances and charge transfer resistances of the electrodes; this fact was assigned to phosphoric acid losses from the electrodes and membrane and catalyst particle size growth.     

Methanol steam reforming in a planar wash coated microreactor integrated with a micro-combustor

A numerical simulation of methanol steam reforming in a microreactor integrated with a methanol micro-combustor is presented. Typical Cu/ZnO/Al₂O₃ and Pt catalysts are considered for the steam reforming and combustor channels respectively. The channel widths are considered at 700 μm in the baseline case, and the reactor length is taken at 20 mm. Effects of Cu/ZnO catalyst thickness, gas hourly space velocities of both steam reforming and combustion channels, reactor geometry, separating substrate properties, as well as inlet composition of the steam reforming channel are investigated. Results indicate that increasing catalyst thickness will enhance hydrogen production by about 68% when the catalyst thickness is increased from 10 μm to 100 μm. Gas space velocity of the steam reforming channel shows an optimum value of 3000 h⁻¹ for hydrogen yield, and the optimum value for the space velocity of the combustor channel is calculated at 24,000 h⁻¹. Effects of inlet steam to carbon ratio on hydrogen yield, methanol conversion, and CO generation are also examined. In addition, effects of the separating substrate thickness and material are examined. Higher methanol conversion and hydrogen yield are obtained by choosing a thinner substrate, while no significant change is seen by changing the substrate material from steel to aluminum with considerably different thermal conductivities. The produced hydrogen from an assembly of such microreactor at optimal conditions will be sufficient to operate a low-power, portable fuel cell.     

Methanol steam reforming over highly efficient CuO–Al2O3 nanocatalysts synthesized by the solid-state mechanochemical method

CH₃OH steam reforming is an attractive way to produce hydrogen with high efficiency. In this study, CuO.xAl₂O₃ (x = 1, 2, 3, and 4) were fabricated based on the solid-state route, and the calcined samples were employed in methanol steam reforming at atmospheric pressure and in the temperature range of 200–450 °C. The results revealed that all samples have a high BET area (173–275 m² g⁻¹), and their crystallinity was reduced by increasing the alumina content in the catalyst formulation. The catalytic activity tests showed that the CH₃OH conversion and H₂ selectivity decreased by rising the Al₂O₃·CuO molar ratio. The methanol conversion enhanced from 13% to 85% by increasing the reaction temperature from 200 °C to 450 °C over the CuO·Al₂O₃ catalyst, due to the higher reducibility of this catalyst at lower temperatures compared to other prepared samples. The influence of calcination temperature (300–500 °C), GHSV (28,000–48000 ml h⁻¹. g⁻¹_cat), feed ratio (C:W = 1:1 to 1:9), and reduction temperature (250–450 °C) was also determined on the yield of the chosen sample. The results revealed that the maximum methanol conversion decreased from 90 to 79% by raising the calcination temperature from 300 to 500 °C due to the reduction of surface area and sintering of species at high calcination temperatures.     

Methanol steam reforming in a microchannel reactor by Zn-, Ce- and Zr- modified mesoporous Cu/SBA-15 nanocatalyst

Hydrogen production by steam reforming of methanol was studied over several Cu/SAB-15-based nanocatalysts in a parallel-type microchannel reactor. The catalysts were prepared through impregnation method and XRD, BET, FT-IR, FE-SEM, TEM, H₂-TPR and TGA techniques were used to characterize surface and structural properties of the synthesized catalysts. The effects of reaction temperature, WHSV and S/C molar ratio on the methanol conversion and selectivities of the gaseous products were studied. Then, effects of the metallic promoters were investigated to improve performance of the catalysts. It was revealed that ZnO and CeO₂ promoters have positive effects on decreasing CO selectivity and ZrO₂ promotes methanol conversion. Furthermore, ZrO₂ and CeO₂ were declared to improve stability of the catalyst. Among the evaluated catalysts, Cu/ZnO/CeO₂/ZrO₂/SBA-15 can provide optimal methanol conversion with low CO concentration in the gaseous products. For this catalyst, the methanol conversion and hydrogen selectivity reached 95.2% and 94.6%, respectively.     

Influence of preparation methods and Zr and Y promoters on Cu/ZnO catalysts used for methanol steam reforming

Binary Cu/ZnO catalysts were prepared using three different methods (coprecipitation, sequential precipitation and homogeneous precipitation) and tested in a methanol steam reforming reaction. Zirconium and yttrium were tested as promoters, and their effects were evaluated in the same reaction. The studied preparation methods influenced the surface area of the Cu-based catalysts and consequently their catalytic activity; however, we verified that surface area was not the only factor influencing activity. Different structural changes in the aurichalcite precursor resulted from the different preparation methods used, and these differences were also observed in the reduced catalysts. An expansion of the Cu lattice with an increase in microstrain were identified and attributed to the formation of a Cu–Zn alloy. Based on the correlation found between these structural changes and the catalytic activity, the Cu–Zn alloy was proposed as active site. We concluded that the preparation methods used influenced Cu dispersion and overall catalyst structure, and Cu–Zn alloy formation resulted from the incorporation of Zn atoms into the Cu lattice. This influence was more pronounced in the catalysts prepared by homogeneous precipitation and coprecipitation. The yttrium promoter did not provide textural or structural advantages. In contrast, the incorporation of Zr promoted both greater Cu dispersion and structural changes in the Cu lattice.     

Cu supported on ZnAl-LDHs precursor prepared by in-situ synthesis method on γ-Al2O3 as catalytic material with high catalytic activity for methanol steam reforming

A novel catalyst precursor ZnAl-LDHs/γ-Al₂O₃ was prepared by in-situ synthesis method, and the copper was supported on calcined hydrotalcite catalyst precursor by wet impregnation. The correlation between the structure and the catalytic activity for methanol steam reforming was studied by XRD, SEM, TPR, chemisorption N₂O, IR and N₂ adsorption techniques. The results showed that the ZnAl-LDHs was successfully synthesized by in-situ synthesis method on γ-Al₂O₃ and the copper mass fraction had a great effect on the interactions between support and copper species. Furthermore, the catalyst reducibility and copper surface area evidently influenced catalytic activity for methanol steam reforming. The 10% Cu/γ-Al@MMO exhibited the best catalytic activity, that was, the methanol conversion was 99.98% and the CO concentration was only 0.92% at 300 °C in hydrogen production by methanol steam reforming.     

Integrated methanol reforming and oxidation in wash-coated microreactors: A three-dimensional simulation

A microreactor consisting of two parallel channels is numerically simulated where methanol steam reforming takes place in one channel, and the required heat is supplied by methanol oxidation in the other channel. Effects of different parameters on methanol conversion, hydrogen yield and CO concentration are examined. Results from the parametric study are then used to propose conditions for high methanol conversion and hydrogen yield. A microreactor with enhanced output conditions is thus designed which is capable of producing a gas stream consisting of 74% hydrogen (dry). CO concentration in the generated synthesis gas stream is low enough to require only a PROX reactor for CO clean-up, eliminating the need for a bulky water–gas shift reactor. The produced hydrogen from an assembly of such microreactors can feed a low-power PEM fuel cell. A cluster of these microreactors would take a volume of about 91 cm³ to feed a typical 30-watt PEM fuel cell.     

Methanol steam reforming in microreactor with constructal tree-shaped network

The construcal tree-shaped network is introduced into the design of a methanol steam microreactor in the context of optimization of the flow configuration. A three-dimensional model for methanol steam reaction in this designed microreactor is developed and numerically analyzed. The methanol conversion, CO concentration in the product and the total pressure drop of the gases in the microreactor with constructal tree-shaped network are evaluated and compared with those in the serpentine reactor. It is found that the reaction of methanol steam reforming is enhanced in the constructal tree-shaped microreactor, since the tree-shaped reactor configuration, which acts an optimizer for the reactant distribution, provides a reaction space with larger surface-to-volume ratio and the reduction of reactant velocities in the branches. Compared with the serpentine microreactor, the constructal reactor possesses a higher methanol conversion rate accompanied with a higher CO concentration. The conversion rate of the constructal microreactor is more than 10% over that of serpentine reactor. More particularly, the reduction of flow distance makes the constructal microreactor still possess almost the same pressure drop as the corresponding serpentine reactor, despite that the bifurcations induce extra local pressure loss, and the reduction of channel size in branches also causes pressure losses.     

High-purity hydrogen production by sorption-enhanced methanol steam reforming over a combination of Cu–Zn–CeO2–ZrO2/MCM-41 catalyst and (Li–Na–K) NO3·MgO adsorbent

In this study, sorption-enhanced methanol steam reforming (SEMSR) was applied to generate high-purity hydrogen. The mesoporous MCM-41 as support and CuO, ZnO, CeO₂, ZrO₂ as active agents and promoters were employed for the catalyst preparation. In addition, (Li–Na–K) NO₃·MgO as a CO₂ adsorbent was prepared by the wet mixing method. The fresh and used catalysts were characterized by XRD, BET, FTIR, FESEM, TEM, H₂-TPR and TGA analyses. Also, the CO₂ sorbent was studied by XRD, BET, FESEM, TEM and TGA analyses before and after the reaction. The SEMSR performances of the synthesized catalyst and adsorbent were evaluated experimentally in a fixed-bed reactor. The effect of various conditions such as temperature, WHSV, feed molar ratio and sorbent/catalyst ratio were investigated. The best results were obtained at 300 °C, a feed molar ratio (water/methanol) of 2:1, a WHSV of 1.62 h^?1, and the sorbent/catalyst ratio of 8:1, which produced 99.8% hydrogen, 25% more than the hydrogen production during conventional methanol steam reforming. Moreover, the cyclic stability of the catalyst and the sorbent was studied for 10 cycles.     

One-step growth of CuO/ZnO/CeO2/ZrO2 nanoflowers catalyst by hydrothermal method on Al2O3 support for methanol steam reforming in a microreactor

CuO/ZnO/CeO₂/ZrO₂ nanoflowers catalyst was grown on an Al₂O₃ foam ceramic by a one-step hydrothermal process, while a naked Al₂O₃ foam ceramic and an Al₂O₃ foam ceramic grown with ZnO nanorods that directly impregnated into the catalyst precursor solution were also fabricated simultaneously. The morphology, composition, redox property and specific surface area of catalysts on the three ceramics were investigated in detail. The catalyst-loaded ceramics were used as catalyst supports in a microreactor to study the catalytic performance for methanol steam reforming. Results showed that the microreactor with Al₂O₃ support grown with nanoflowers catalyst achieved 99.8% methanol conversion rate, 0.16 mol/h H₂ flow rate at 310 °C, and an inlet methanol flow rate of 0.048 mol/h. Moreover, the microreactor exhibited 92% methanol conversion rate after 30 h continuous reaction.     

Characterization and activity test of commercial Ni/Al2O3, Cu/ZnO/Al2O3 and prepared Ni–Cu/Al2O3 catalysts for hydrogen production from methane and methanol fuels

In this study, methane and methanol steam reforming reactions over commercial Ni/Al₂O₃, commercial Cu/ZnO/Al₂O₃ and prepared Ni–Cu/Al₂O₃ catalysts were investigated. Methane and methanol steam reforming reactions catalysts were characterized using various techniques. The results of characterization showed that Cu particles increase the active particle size of Ni (19.3 nm) in Ni–Cu/Al₂O₃ catalyst with respect to the commercial Ni/Al₂O₃ (17.9). On the other hand, Ni improves Cu dispersion in the same catalyst (1.74%) in comparison with commercial Cu/ZnO/Al₂O₃ (0.21%). A comprehensive comparison between these two fuels is established in terms of reaction conditions, fuel conversion, H₂ selectivity, CO₂ and CO selectivity. The prepared catalyst showed low selectivity for CO in both fuels and it was more selective to H₂, with H₂ selectivities of 99% in methane and 89% in methanol reforming reactions. A significant objective is to develop catalysts which can operate at lower temperatures and resist deactivation. Methanol steam reforming is carried out at a much lower temperature than methane steam reforming in prepared and commercial catalyst (275–325 °C). However, methane steam reforming can be carried out at a relatively low temperature on Ni–Cu catalyst (600–650 °C) and at higher temperature in commercial methane reforming catalyst (700–800 °C). Commercial Ni/Al₂O₃ catalyst resulted in high coke formation (28.3% loss in mass) compared to prepared Ni–Cu/Al₂O₃ (8.9%) and commercial Cu/ZnO/Al₂O₃ catalysts (3.5%).