ALTERNATIVE GENERATION OF H2, CO AND H2, CO2 MIXTURES FROM STEAM-CARBON DIOXIDE REFORMING OF METHANE AND THE WATER GAS SHIFT WITH PERMEABLE (MEMBRANE) REACTORS

A new process is proposed which converts CO₂ and CH₄ containing gas streams to synthesis gas, a mixture of CO and H₂ via the catalytic reaction scheme of steam-carbon dioxide reforming of methane or the respective one of only carbon dioxide reforming of methane, in permeable (membrane) reactors. The membrane reformer (permreactor) can be made by reactive or inert materials such as metal alloys, microporous ceramics, glasses and composites which all are hydrogen permselective. The rejected CO reacts with steam and converted catalytically to CO₂ and H₂ via the water gas shift in a consecutive permreactor made by similar to the reformer materials and alternatively by high glass transition temperature polymers. Both permreactors can recover H₂ in permeate by using metal membranes, and H₂ rich mixtures by using ceramic, glass and composite type permselective membranes. H₂ and CO₂ can be recovered simultaneously in water gas shift step after steam condensation by using organic polymer membranes. Product yields are increased through permreactor equilibrium shift and reaction separation process integration.

CO and H₂ can be combined in first step to be used for chemical synthesis or as fuel in power generation cycles. Mixtures of CO₂ and H₂ in second step can be used for synthesis as well (e.g., alternative methanol synthesis) and as direct feed in molten carbonate fuel cells. Pure H₂ from the above processes can be used also for synthesis or as fuel in power systems and fuel cells. The overall process can be considered environmentally benign because it offers an in-situ abatement of the greenhouse CO₂ and CH₄ gases and related hydrocarbon-CO₂ feedstocks (e.g., coal, landfill, natural, flue gases), through chemical reactions, to the upgraded calorific value synthesis gas and H₂, H₂ mixture products.     

CO2 reforming of methane to syngas: I: evaluation of hydrotalcite clay-derived catalysts

Several important chemicals can potentially be manufactured from natural gas (mostly methane) by first converting it to syngas (CO+H₂). The high cost of converting methane to syngas currently limits the large scale commercial use of syngas to produce methanol. This study focuses on the CO₂/steam reforming of methane to produce inexpensive syngas using nickel and magnesium containing hydrotalcite clay-derived catalysts. Several of these catalysts were prepared and evaluated. The results are compared with commercial Ni/Al₂O₃ or Ni/MgAl₂O₄ catalysts. At 815°C and 300 psi pressure, the fresh clay-derived catalysts showed identical performance as the commercial catalysts. However, under more severe operating conditions, the clay-derived catalysts exhibited superior activity and stability. Aging studies clearly showed that the clay-derived catalysts are more stable and coke resistant than commercial catalysts.     

Synthesis gas production using steam hydrogasification and steam reforming

Experimental work has been carried out on the mixed reforming reaction, i.e., simultaneous steam and CO₂ reforming of methane under a wide range of feed compositions and four different reaction temperatures from 700 °C to 850 °C using a commercial steam reforming catalyst. The experiments were conducted for a CO₂/CH₄ ratio from 0 to 2 and a steam to methane ratio from 3 to 5. The effect of CO₂/CH₄ ratio on the exit H₂/CO ratio and the conversions of the reactants indicate that the dry reforming reaction is dominant under increased carbon dioxide in the feed. Steam reforming of typical steam hydrogasification product gas consisting of CO, H₂ and CO₂ in addition to steam and methane has also been investigated. The H₂/CO ratio of the product synthesis gas varies from 4.3 to 3.7 and from 4.8 to 4.1 depending on the feed composition and reaction temperature. The CO/CO₂ ratios of the synthesis gas varied from 1.9 to 2.9 and 2.0 to 3.3. The results are compared with simulation results obtained through the Aspen Plus process simulation tool. The results demonstrate that a coupled steam hydrogasification and reforming process can generate a synthesis gas with a flexible H₂/CO ratio from carbon-containing feedstocks.     

Improved resistance against coke deposition of titania supported cobalt and nickel bimetallic catalysts for carbon dioxide reforming of methane

The catalytic behavior of bi-metallic Co–Ni/TiO₂ catalysts for CO₂ reforming of CH₄ to synthesis gas was investigated under atmospheric pressure with a particular attention to carbon deposition. The catalysts with optimized Co/Ni ratios showed high catalytic stability towards the reaction with very little amount of deposited carbon at a wide range of reaction temperature (773–1123 K). The results suggest that adjusting of composition of the active metals (Co and Ni) can kinetically control the elementary steps (formation of carbon species and its removal by oxygen species) of CH₄/CO₂ reaction.     

Heat transport limitations and reaction scheme of partial oxidation of methane to synthesis gas over supported rhodium catalysts

The partial oxidation of methane to synthesis gas over supported Rh catalysts is investigated, paying particular attention to removing heat transport limitations and identifying the reaction conditions within the kinetic-controlling regime. The results obtained suggest that the reaction follows the sequence of total oxidation to CO₂ and H₂O, followed by reforming reactions to synthesis gas.     

Partial oxidation of methane to synthesis gas via the direct reaction scheme over Ru/TiO2 catalyst

The partial oxidation of methane to synthesis gas has been investigated over various supported metal catalysts. The effects of operational variables on mass and heat transport resistances were investigated for defining the kinetic regime. It is observed that, in the absence of significant mass and heat transfer resistances, high selectivity (up to 65%) to synthesis gas is obtained over Ru/TiO₂ catalysts in the low methane conversion range ( ) whereas only negligibly small selectivity to synthesis gas is observed over all other catalysts investigated under similar conditions. This indicates that the Ru/TiO₂ catalyst possesses unique properties, offering high selectivity to synthesis gas formation via the direct reaction scheme, whereas the other catalysts promote the sequence of total oxidation of methane to CO₂ and H₂O, followed by reforming reactions to synthesis gas. An increase of selectivity to synthesis gas, in the presence of oxygen, is achieved over the Ru/TiO₂ catalyst by multi-feeding oxygen, which is attributed to suppression of deep oxidation of H₂ and CO.     

Catalytic syngas production from greenhouse gasses: Performance comparison of Ru-Al2O3 and Rh-CeO2 catalysts

In this work, 3% Ru-Al₂O₃ and 2% Rh-CeO₂ catalysts were synthesized and tested for CH₄-CO₂ reforming activity using either CO₂-rich or CO₂-lean model biogas feed. Low carbon deposition was observed on both catalysts, which negligibly influenced catalytic activity. Catalyst deactivation during temperature programmed reaction was observed only with Ru-Al₂O₃, which was caused by metallic cluster sintering. Both catalysts exhibited good stability during the 70 h exposure to undiluted equimolar CH₄/CO₂ gas stream at 750 °C. By varying residence time in the reactor during CH₄-CO₂ reforming, very similar quantities of H₂ were consumed for water formation. Reverse water-gas shift (RWGS) reaction occurred to a very similar extent either with low or high WHSV values over both catalysts, revealing that product gas mixture contained near RWGS equilibrium composition, confirming the dominance of WGS reaction and showing that shortening the contact time would actually decrease the H₂/CO ratio in the syngas produced by CH₄-CO₂ reforming, as long as RWGS is quasi equilibrated. H₂/CO molar ratio in the produced syngas can be increased either by operating at higher temperatures, or by using a feed stream with CH₄/CO₂ ratio well above 1.     

Effect of support on the conversion of methane to synthesis gas over supported iridium catalysts

A partial oxidation of methane was carried out using iridium catalysts supported on several metal oxides. The productivity of the synthesis gas from methane was strongly affected by the choice of support oxides for the catalysts. The synthesis gas production proceeded basically via a two-step reaction consisting of methane combustion to give H₂O and CO₂, followed by the reforming of methane from CO₂ and steam. Although the combustion and the reforming of methane from steam did not depend upon the catalyst support, a large variation in the catalytic activity for the reforming of methane from CO₂ was observed over Ir catalysts with different supports. The support activity order in the reforming of methane from CO₂ with iridium catalysts was as follows: TiO₂≧ZrO₂≧Y₂O₃>La₂O₃>MgO≧Al₂O₃>SiO₂. The same order was observed in the synthesis gas production from the partial oxidation of methane. This revised version was published online in August 2006 with corrections to the Cover Date.     

On the contribution of X-ray absorption spectroscopy to explore structure and activity relations of Pt/ZrO2 catalysts for CO2/CH4 reforming

X-ray absorption spectroscopy (XAS) has proven to be a very useful technique in characterizing metal-based catalysts exposed to extreme operating conditions. The technique allows in situ evaluation of structural parameters (XAFS) and electronic properties (XANES). The elucidation of the nature and state of Pt-based catalysts in dry reforming of methane with carbon dioxide is presented as case study to show the contribution and potential of XAS to explore property/performance relationships for heterogeneous catalysts. Pt/ZrO₂ is an active and stable catalyst for the reaction between CH₄ and CO₂ to synthesis gas (H₂/CO). The activity and stability of the catalyst is strongly influenced by the catalyst pretreatment (calcination/reduction). The combination of hydrogen chemisorption, IR spectroscopy, XPS and XAS is shown to be suitable to track the changes of the state of the catalyst. In particular, it will be demonstrated, how XAFS helped to correctly attribute variations in the chemisorptive properties of Pt/ZrO₂ after severe temperature treatment to partial and reversible decoration of the small Pt particles with fragments of the oxide support. In situ tracking of the reduction of the catalysts by XANES additionally helped to semiquantitatively assess the partial reduction of the ZrO₂. Finally, XANES helped to demonstrate that CO₂ exposure under these severe conditions did not lead to detectable levels of surface oxidation of Pt. Based on XANES, IR spectroscopy and kinetic measurements it is concluded that in dry reforming activation of methane occurs on Pt, while CO₂ is activated on the support and the two entities react at the metal–support interface. This revised version was published online in June 2006 with corrections to the Cover Date.     

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

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

Conversions of Methane to Synthesis Gas over Co/γ-Al2O3 by CO2 and/or O2

The goal of the paper was to investigate the effect of the catalyst precursor on the catalytic activity. For this reason, the structure, the reducibility and the reaction behavior of -Al₂O₃-supported Co (24 wt%) catalysts as a function of calcination temperature (T _c) were investigated using X-ray diffraction, temperature-programmed reduction, CO chemisorption, pulse reaction with pure CH₄, and the catalytic reactions of methane conversion to synthesis gas. Depending on T _c, one, two, or three of the following Co-containing compounds, Co₃O₄, Co₂AlO₄, and CoAl₂O₄, were identified. Their reducibility decreased in the sequence: Co₃O₄>Co₂AlO₄>CoAl₂O₄. Co₃O₄ was generated as a major phase at a T _c of 500°C and Co₂AlO₄ and CoAl₂O₄ at a T _c of 1000°C. The reduced Co/-Al₂O₃ catalysts, obtained via the reduction of the 500 and 1000°C calcined catalysts, provided high and stable activities for the partial oxidation of methane and the combined partial oxidation and CO₂ reforming of methane. They deactivated, however, rapidly in the CO₂ reforming of methane. Possible explanations for the stability are provided.     

Methane steam reforming for synthetic diesel fuel production from steam-hydrogasifier product gases

Steam-methane reforming (SMR) reaction was studied using a tubular reactor packed with NiO/γ-Al₂O₃ catalyst to obtain synthesis gases with H₂/CO ratios optimal for the production of synthetic diesel fuel from steam-hydrogasification of carbonaceous materials. Pure CH₄ and CH₄-CO₂ mixtures were used as reactants in the presence of steam. SMR runs were conducted at various operation parameters. Increasing temperature from 873 to 1,023 K decreased H₂/CO ratio from 20 to 12. H₂/CO ratio decreased from 16 to 12 with pressure decreasing from 12.8 to 1.7 bars. H₂/CO ratio also decreased from about 11 to 7 with steam/CH₄ ratio of feed decreasing from 5 to 2, the lowest limit to avoid severe coking. With pure CH₄ as the feed, H₂/CO ratio of synthesis gas could not be lowered to the optimal range of 4–5 by adjusting the operation parameters; however, the limitation in optimizing the H₂/CO ratio for synthetic diesel fuel production could be removed by introducing CO₂ to CH₄ feed to make CH₄-CO₂ mixtures. This effect can be primarily attributed to the contributions by CO₂ reforming of CH₄ as well as reverse water-gas shift reaction, which led to lower H₂/CO ratio for the synthesis gas. A simulation technique, ASPEN Plus, was applied to verify the consistency between experimental data and simulation results. The model satisfactorily simulated changes of H₂/CO ratio versus the operation parameters as well as the effect of CO₂ addition to CH₄ feed.     

Combined catalytic partial oxidation and CO2 reforming of methane over supported cobalt catalysts

The combined partial oxidation and CO₂ reforming of methane to synthesis gas was investigated over the reduced Co/MgO, Co/CaO, and Co/SiO₂ catalysts. Only Co/MgO has proved to be a highly efficient and stable catalyst. It provided about 94–95% yields to H₂ and CO at the high space velocity of 105000 mlg^–1h^–1 and for feed ratios CH₄/CO₂/O₂=4/2/1, without any deactivation for a period of study of 110 h. In contrast, the reduced Co/CaO and Co/SiO₂ provided no activity for the formation of H₂ and CO. The structure and reducibility of the calcined catalysts were examined using X-ray diffraction and temperature-programmed reduction, respectively. A solid solution of CoO and MgO, which was difficult to reduce, was identified in the 800°C calcined MgO-supported catalyst. The strong interactions induced by the formation of the solid solution are responsible for its superior activity in the combined reaction. The effects of reaction temperature, space velocity, and O₂/CO₂ ratio in the feed gases (while keeping the C/O ratio constant at 1/1) were investigated over the Co/MgO catalyst. The H₂/CO ratio in the product of the combined reaction increased with increasing O₂/CO₂ ratio in the feed.     

Carbon Dioxide Reforming of Methane Over Nanocomposite Ni/ZrO2 Catalysts

A systematic study of the size effect of zirconia nanocrystals on nickel-catalyzed reforming of methane with CO₂ shows that extremely stable Ni/ZrO₂ catalysts are obtainable by hydrogen reduction of impregnated nickel nitrate on zirconia particles with sizes less than 25 nm. The same preparation method with larger particles of zirconia results in catalyst samples that deactivate rapidly in the reforming reaction. Comprehensive characterization with XRD, TPR/TPD, and TEM shows that the stable Ni/ZrO₂ catalysts are better described as nanocomposites of size comparable to Ni metal (9-15 nm) and zirconia (7-25 nm) nanoparticles. The high percentage of the Ni-zirconia boundary or perimeter in the nanocomposite catalysts is believed to be crucial for the extremely stable catalytic activity.     

CH4/CD4 isotope effects in the carbon dioxide reforming of methane to syngas over SiO2-supported nickel catalysts

By performing the CH₄ + CO₂ and CD₄ + CO₂ reactions alternately over SiO₂-supported nickel catalysts in a pulse micro-reactor, normal deuterium isotope effects on both the methane conversion reaction and on the CO formation reaction have been observed in the process of CO₂ reforming of methane. Based on the observed CH₄/CD₄ isotope effects, the pathways for the formation of CO are discussed.     

Mechanistic study of partial oxidation of methane to synthesis gas over supported rhodium and ruthenium catalysts using in situ time-resolved FTIR spectroscopy

In situ time-resolved FTIR spectroscopy was used to study the reaction mechanism of partial oxidation of methane to synthesis gas and the interaction of CH₄/O₂/He (2/1/45) gas mixture with adsorbed CO species over SiO₂ and γ-Al₂O₃ supported Rh and Ru catalysts at 500–600°C. It was found that CO is the primary product for the reaction of CH₄/O₂/He (2/1/45) gas mixture over H₂ reduced and working state Rh/SiO₂ catalyst. Direct oxidation of methane is the main pathway of synthesis gas formation over Rh/SiO₂ catalyst. CO₂ is the primary product for the reaction of CH₄/O₂/He (2/1/45) gas mixture over Ru/γ-Al₂O₃ and Ru/SiO₂ catalysts. The dominant reaction pathway of CO formation over Ru/γ-Al₂O₃ and Ru/SiO₂ catalysts is via the reforming reactions of CH₄ with CO₂ and H₂O. The effect of space velocity on the partial oxidation of methane over SiO₂ and γ-Al₂O₃ supported Rh and Ru catalysts is consistent with the above mechanisms. It is also found that consecutive oxidation of surface CO species is an important pathway of CO₂ formation during the partial oxidation of methane to synthesis gas over Rh/SiO₂ and Ru/γ-Al₂O₃ catalysts.     

A novel process for converting coalmine-drained methane gas to syngas over nickel–magnesia solid solution catalysts

A novel process is developed in this paper for utilizing the coalmine-drained methane gas that is usually vented straight into the atmosphere in most coalmines worldwide. It is expected that low-cost syngas can be produced by the combined air partial oxidation and CO₂ reforming of methane, because this process utilizes directly the methane, air, and carbon dioxide in the coalmine-drained gas without going through the separation step. For this purpose, a nickel–magnesia solid solution catalyst was prepared and its catalytic performance for the proposed process was investigated. It was found that calcination temperature has significant influence on the catalytic performance due to the different extent of solid solution formation in the catalysts. A uniform nickel–magnesia solid solution catalyst exhibits higher stability than the catalysts in which NiO has not completely formed solid solution with MgO. Its catalytic activity and selectivity remain stable during 120 h of reaction. The product H₂/CO ratio is mainly dependent on the feed gas composition. By changing CO₂/air ratio of the feed gases, syngas with a H₂/CO ratio between 1 and 1.9 can be obtained. The influences of reaction temperature and nickel loading on the catalytic performance were also investigated.     

Hydrogen production via chemical looping dry reforming of methane: Process modeling and systems analysis

The present study presents and analyses a family of “chemical looping dry reforming” (CLDR) processes that produce inherently separated syngas (H₂ and CO) streams via a combination of methane cracking in a “cracker reactor” and the Boudouard reaction (i.e., conversion of the formed carbon with CO₂ to CO) in a “CO₂ reactor,” and then further maximize the H₂ yield via conversion of the produced CO via water-gas-shift. Remaining CO₂ emissions are minimized via CO₂ capture and sequestration. Four different configurations are evaluated which differ in how the heat required for the highly endothermic dry reforming reaction is supplied: (i) combustion of additional CH₄ feed (CLDR-CH₄); (ii) combustion of some of the CO produced in the CO₂ reactor (CLDR-CO); and combustion of some of the carbon produced in the cracker reactor with (iii) pure oxygen (CLDR-C-oxy); or (iv) with air (CLDR-C-air). Process models are developed to comparatively analyze the mass and energy balances of these configurations, and benchmark them against H₂-production via conventional dry reforming and steam reforming of methane. Our results show that CLDR-C-oxy is the most promising H₂-production pathway among the chemical looping and conventional technologies both in terms of chemical energy efficiency and in terms CO₂ emissions. Thus, the unique flexibility offered by the production of inherently separated syngas streams in CLDR enables overcoming the disadvantage of the strongly endothermic dry reforming reaction by combusting carbon internally in the reactor and thus achieving highly effective heat integration. Overall, the results support the technical viability and demonstrate the promise for strong process intensification of CLDR compared to conventional dry reforming and even steam reforming, the most widely used H₂-production pathway to-date.     

甲烷二氧化碳催化重整制合成气研究进展

催化剂研究是实现甲烷二氧化碳重整制合成气工业化的关键。对近年来甲烷二氧化碳重整制合成气的催化剂研究进行综述。介绍了贵金属催化剂、非贵金属催化剂及碳化物催化剂在甲烷二氧化碳重整反应中的应用及反应机理,并对催化剂体系研究方向进行展望。