CO2 reforming of CH4 over nanocrystalline zirconia-supported nickel catalysts

Mesoporous nanocrystalline zirconia with high-surface area and pure tetragonal crystalline phase has been prepared by the surfactant-assisted route, using Pluronic P123 block copolymer surfactant. The synthesized zirconia showed a surface area of 174 m² g⁻¹ after calcination at 700 °C for 4 h. The prepared zirconia was employed as a support for nickel catalysts in dry reforming reaction. It was found that these catalysts possessed a mesoporous structure and even high-surface area. The activity results indicated that the nickel catalyst showed stable activity for syngas production with a decrease of about 4% in methane conversion after 50 h of reaction. Addition of promoters (CeO₂, La₂O₃ and K₂O) to the catalyst improved both the activity and stability of the nickel catalyst, without any decrease in methane conversion after 50 h of reaction.     

Structure and reactivity of plasma treated Ni/Al2O3 catalyst for CO2 reforming of methane

The glow discharge plasma treated Ni/Al₂O₃ catalyst showed an excellent anti-coke property for CO₂ reforming of methane. Characterizations using X-ray powder diffraction (XRD), X-ray photoelectron spectroscopy (XPS), temperature programmed reduction (TPR), transmission electron microscopy (TEM), and CO adsorbed infrared spectroscopy (IR) were conducted to investigate the structure and reactivity of the plasma treated Ni/Al₂O₃ catalyst for CO₂ reforming of methane. It confirms that the plasma treatment of Ni precursor at room temperature followed by calcination thermally has a significant influence on the surface characteristics of the active phase. The plasma treated catalyst contains high concentration of close packed plane with improved Ni dispersion and enhanced Ni-alumina interaction, which lead to high catalytic activity and excellent resistance to formations of filamentous carbon and encapsulating carbon.     

Synthesis of carbon-supported nickel catalysts for the dry reforming of CH4

A series of carbon-based nickel (Ni) catalysts was prepared in order to investigate the effect of the preparation method on the dispersion of Ni and its final catalytic activity in the dry reforming of methane, i.e. CH₄ + CO₂ = 2H₂ + 2CO. Three parameters were studied: (i) the influence of the surface chemistry of the carbon used as support; (ii) the method of drying (conventional vs. microwave drying); and, (iii) the temperature of the reduction stage. In order to study the role of the surface chemistry of the commercial activated carbon used as support, the active carbon was tested as received and oxidized. Although a better Ni dispersion was achieved over the oxidized support, the conversions were much lower. It was also found that microwave drying offers various advantages over conventional drying, the main one being that less time is required to prepare the catalyst. Two reduction temperatures were used (300 and 500 °C), being found that it is necessary to adjust this parameter to prevent the Ni particles from sintering.     

Transient modeling of combined catalytic combustion/CH4 steam reforming

This paper presents an investigation into the complex interactions between catalytic combustion and CH₄ steam reforming in a co-flow heat exchanger where the surface combustion drives the endothermic steam reforming on opposite sides of separating plates in alternating channel flows. To this end, a simplified transient model was established to assess the stability of a system combining H₂ or CH₄ combustion over a supported Pd catalyst and CH₄ steam reforming over a supported Rh catalyst. The model uses previously reported detailed surface chemistry mechanisms, and results compared favorably with experiments using a flat-plate reactor with simultaneous H₂ combustion over a γ-Al₂O₃-supported Pd catalyst and CH₄ steam reforming over a γ-Al₂O₃-supported Rh catalyst. Results indicate that stable reactor operation is achievable at relatively low inlet temperatures (400 °C) with H₂ combustion. Model results for a reactor with CH₄ combustion indicated that stable reactor operation with reforming fuel conversion to H₂ requires higher inlet temperatures. The results indicate that slow transient decay of conversion, on the order of minutes, can arise due to loss of combustion activity from high-temperature reduction of the Pd catalyst near the reactor entrance. However, model results also show that under preferred conditions, the endothermic reforming can be sustained with adequate conversion to maintain combustion catalyst temperatures within the range where activity is high. A parametric study of combustion inlet stoichiometry, temperature, and velocity reveals that higher combustion fuel/air ratios are preferred with lower inlet temperatures (≤500 °C) while lower fuel/air ratios are necessary at higher inlet temperatures (600 °C).     

The role of the oxidic support on the deactivation of Pt catalysts during the CO2 reforming of methane

Pt supported on γ-Al₂O₃, TiO₂ and ZrO₂ are active catalysts for the CO₂ reforming of methane to synthesis gas. The stability of the catalysts increased in the order Pt/γ-A1₂O₃ < Pt/TiO₂ < Pt/ZrO₂. For all catalysts, the decrease in activity with time on stream is caused by carbon formation, which blocks the active metal sites for reaction. With Pt/TiO₂ and Pt/ZrO₂, deactivation started immediately after the start of the reaction, while the Pt/γ-A1₂O₃ catalyst showed an induction period during which carbon was accumulated without affecting the catalytic activity.     

Combined CO2 reforming and partial oxidation of n-heptane on noble metal zirconia catalysts

The combined CO₂ reforming and partial oxidation (POX) of n-heptane was studied on various noble metal zirconia catalysts between 700 and 900 °C. The activity order of the metals was Rh > Pd > Ir > Pt. Selectivity to syngas increased with the activity of the catalysts but the H₂ to CO molar ratio decreased. The activity and selectivity of the 0.25 wt% Rh/ZrO₂ catalyst were close to the performance of a commercial 15 wt% NiO/Al₂O₃ catalyst. The conversions and product compositions were compared to the calculated thermodynamic equilibria.     

Monolithic-like TiO2 nanotube supported Ru catalyst for activation of CH4 and CO2 to syngas

Highly-ordered TiO₂ nanotube arrays (TiNTA) were prepared by an electrochemical anodization method and used as the carrier material to load 1 wt.% Ru. The Ru/TiNTA catalyst was then applied to the combination reactions of the partial oxidation of methane reaction (POM) with the carbon dioxide reforming with methane reaction (CRM) for syngas production. In comparison with the commercial TiO₂ powder (P25) supported 1 wt.% Ru catalyst, Ru/TiNTA shows higher activity and much better stability. The superior performance of Ru/TiNTA is attributed to the specific monolithic-like structure and confinement effect of TiNTA.     

CO2 reforming of CH4 over stabilized mesoporous Ni-CaO-ZrO2 composites

Mesoporous Ni-CaO-ZrO₂ nanocomposites with high thermal stability were designed and employed in the CO₂/CH₄ reforming. The nanocomposites with appropriate Ni/Ca/Zr molar ratios exhibited excellent activity and prominent coking resistivity. The Ni crystallites were effectively controlled under the critical size for coke formation in such nanocomposites. It was found that low Ni content resulted in high metal dispersion and good catalytic performance. Moreover, the basicity of the matrices improved the chemisorption of CO₂ and promoted the gasification of deposited coke on the catalyst.     

Mixtures of carbon and Ni/Al2O3 as catalysts for the microwave-assisted CO2 reforming of CH4

In this work, the microwave-assisted CO₂ reforming of CH₄ over mixtures of carbonaceous materials and an in-lab prepared Ni/Al₂O₃ was studied. Ni/Al₂O₃ is not heated by microwave radiation, and for this reason, microwave receptors, such as carbonaceous materials, must be mixed with this catalyst. In order to evaluate the role of the carbonaceous component of the blend, two different carbonaceous materials were used: an activated carbon, FY5, and a metallurgical coke, CQ. The carbonaceous component acted not only as microwave receptor but also as catalyst and, consequently, it influenced the catalytic activity of the mixture. FY5 + Ni/Al₂O₃ was found to be a better catalyst than CQ + Ni/Al₂O₃, since FY5 on its own showed a better catalytic activity than CQ. Ni/FY5, which consists of Ni impregnated directly onto the microwave receptor, was also evaluated as a catalyst. It was found that the catalytic activity of the mixture FY5 + Ni/Al₂O₃ was better than that of Ni/FY5. Finally, the influence of the heating device on the catalytic activity of FY5 + Ni/Al₂O₃ was studied. Conversions over FY5 + Ni/Al₂O₃ and microwave heating were found to be similar to conversions over Ni/Al₂O₃ and conventional heating.     

CO2吸附强化CH4/H2O重整制氢催化剂研究进展

CO_2吸附强化CH_4/H_2O重整制氢是提供低成本高纯氢气和实现CO_2减排的方法之一。其中,催化剂和吸附剂是该工艺的重要组成部分,其活性与选择性制约了反应速率和产率,寿命长短关系到生产成本。综述了CO_2吸附强化CH_4/H_2O重整制氢催化剂和吸附剂的研究现状及存在的问题,机械混合的催化剂与吸附剂在反应过程中存在吸附产物包覆催化活性位点的问题,导致催化剂活性迅速下降。针对该问题,进一步探讨了不同结构双功能复合催化剂的结构特性、研究现状及其在循环-再生过程中存在的问题,核壳型双功能催化剂具有吸附组分与催化剂组分相对独立、催化组分分散分布和比表面积大等优点,在吸附强化制氢中有进一步研究的潜力。利用双功能催化剂的结构特点,实现反复循环再生过程中催化与脱碳反应的匹配,是推动CO_2吸附强化CH_4/H_2O重整制氢技术工业化发展的关键。     

Light alkanes CO2 reforming to synthesis gas over Ni based catalysts

The CO₂ reforming of methane and propane has been compared over two different Ni catalysts: one reference Ni/SiO₂ system and a Ni/Mg(Al)O hydrotalcite-derived catalyst, shown previously to display high catalytic stability for long term reforming. By combining the Tapered Element Oscillating Microbalance (TEOM), Temperature Programmed Hydrogenation (TPH), Transmission Electron Microscopy (TEM) and magnetic measurements, the formation of coke and its role on the catalyst activity has been investigated and compared for both hydrocarbons. It was found that Ni/SiO₂ and Ni/Mg(Al)O are both more active for methane reforming than for propane reforming. Coke formation is much more pronounced for propane than for methane over both catalysts. However, for both hydrocarbons a much faster carbon formation is observed over the Ni/SiO₂ catalyst than over the Ni/Mg(Al)O catalyst. The difference in the rates of coke formation for methane and propane is ascribed in the case of propane to partially dehydrogenated C₃ adspecies, which are good coke precursors. The superior stability of the hydrotalcite-derived catalyst is due to the strong interaction of the nickel phase with the support and the capacity of the support to activate CO₂ and channel oxygen to the nickel phase.     

Direct synthesis of acetic acid from CH4 and CO2 by a step-wise route over Pd/SiO2 and Rh/SiO2 catalysts

The theoretical and experimental feasibility of direct conversion of CH₄ and CO₂ to acetic acid by an isothermal step-wise route over Pd/SiO₂ and Rh/SiO₂ catalysts was investigated. The methyl radical formation from CH₄ dissociation and CO₂ inserting into the intermediate are regarded as two limiting steps. Preliminary experimental results have shown that the following step-wise route can circumvent the thermodynamic limitation of this direct synthesis at low temperatures. Pd catalysts are more active than Rh catalysts at 170 °C and 200 °C, while formic acid is only produced on Pd catalysts. The optimum contact time of CH₄ and CO₂ with catalysts is 1 min under the experimental conditions. And there is no apparent deactivation resulting from carbon deposition for catalysts during the successive reaction cycles.     

Syngas production from methane reforming with CO2/H2O and O2 over NiO–MgO solid solution catalyst in fluidized bed reactors

Catalyst performance of NiO–MgO solid solution catalysts for methane reforming with CO₂ and H₂O in the presence of oxygen using fluidized and fixed bed reactors under atmospheric and pressurized conditions was investigated. Especially, methane and CO₂ conversion in the fluidized bed reactor in methane reforming with CO₂ and O₂ was higher than those in the fixed bed reactor over Ni_0.15Mg_0.85O catalyst under 1.0 MPa. In contrast, conversion levels in the fluidized and fixed bed reactor were almost the same over MgO-supported Ni and Pt catalysts. It is suggested that the promoting effect of catalyst fluidization on the activity is related to the catalyst reducibility. On a catalyst with suitable reducibility, the oxidized and deactivated catalyst can be reduced with the produced syngas and the reforming activity regenerates in the fluidized bed reactor during the catalyst fluidization. In addition, the catalyst fluidization inhibited the carbon deposition.     

Bound-state Ni species — a superior form in Ni-based catalyst for CH4/CO2 reforming

The effects of nickel loading, calcination temperature, support, and basic additives on Ni-based catalyst structure and reactivity for CH₄ reforming with CO₂ were investigated. The results show that the structure of the nickel active phase strongly depends on the interactions of the metal and the support, which are related to the support properties, the additives and the preparation conditions. “Free” Ni species can be formed when the interaction is weak and their mobility makes them easily deactivated by coking and sintering. The effect of strong metal-support interaction (SMSI effect) is different for various supports. The formation of solid solution of Ni–Mg–O₂ and the blocking of TiO_x by the partially reduced TiO₂ can both decrease the availability of Ni active sites in Ni/MgO and Ni/TiO₂. The spinel NiAl₂O₄ formed in Ni/γ-Al₂O₃ might be responsible for its high activity and resistance to coking and sintering because it can produce a highly dispersed active phase and a large active surface area as bound-state Ni species when the catalyst is prepared at high calcined temperatures or with low nickel loading. The addition of La₂O₃ or MgO as alumina modifiers can also be beneficial for the performance of the Ni/γ-Al₂O₃ catalyst.     

Catalytic conversion of methane and CO2 to synthesis gas over a La2O3-modified SiO2 supported Ni catalyst in fluidized-bed reactor

In this contribution, a commercial spherical SiO₂ was modified with different amounts of La₂O₃, and used as the support of Ni catalysts for autothermal reforming of methane in a fluidized-bed reactor. Nitrogen adsorption, XRD and H₂-TPR analysis indicated that La₂O₃-modified SiO₂ had higher surface area, strengthened interaction between Ni and support, and improved dispersion of Ni. CO₂-TPD found that La₂O₃ increased the alkalescence of SiO₂ and improved the activation of CO₂. Coking reaction (via both temperature-programmed surface reaction of CH₄ (CH₄-TPSR) and pulse decomposition of CH₄) disclosed that La₂O₃ reduced the dehydrogenation ability of Ni. CO₂-TPO, O₂-TPO (followed after CH₄-TPSR) confirmed that only part amount of carbon species derived from methane decomposition could be removed by CO₂, and O₂ in feed played a crucial role for the gasification of the inactive surface carbons. Ni/xLa₂O₃-SiO₂ (x = 10, 15, 30) possessed high activity and excellent stability for autothermal reforming of methane in a fluidized-bed reactor.     

The effect of CeO2 structure on the activity of supported Pd catalysts used for methane steam reforming

Palladium (Pd) supported on CeO₂-promoted γ-Al₂O₃ with various CeO₂ (ceria) crystallinities, were used as catalysts in the methane steam reforming reaction. X-ray diffraction (XRD) analysis, FTIR spectroscopy of adsorbed CO, and X-ray photoelectron spectroscopy (XPS) were employed to characterize the samples in terms of Pd and CeO₂ structure and dispersion on the γ-Al₂O₃ support. These results were correlated with the observed catalytic activity and deactivation process. Arrhenius plots at steady-state conditions are presented as a function of CeO₂ structure. Pd is present on the oxidized CeO₂-promoted catalysts as Pd⁰, Pd⁺ and Pd²⁺, at ratios strongly dependent on CeO₂ structure. XRD measurements indicated that Pd is well dispersed (particles <2 nm) on crystalline CeO₂ and is agglomerated as large clusters (particles in 10–20 nm range) on amorphous CeO₂. FTIR spectra of adsorbed CO revealed that after pre-treatment under H₂ or in the presence of amorphous CeO₂, partial encapsulation of Pd particles occurs. CeO₂ structure influences the CH₄ steam reforming reaction rates. Crystalline CeO₂ and dispersed Pd favor high reaction rates (low activation energy). The presence of CeO₂ as a promoter conferred high catalytic activity to the alumina-supported Pd catalysts. The catalytic activity is significantly lower on Pd/γ-Al₂O₃ or on amorphous (reduced) CeO₂/Al₂O₃ catalysts. The reaction rates are two orders of magnitude higher on Pd/CeO₂/γ-Al₂O₃ than on Pd/γ-Al₂O₃, which is attributed to a catalytic synergism between Pd and CeO₂. The low rates on the reduced Pd/CeO₂/Al₂O₃ catalysts can be correlated with the loss of Pd sites through encapsulation or particle agglomeration, a process found mostly irreversible after catalyst regeneration.     

NiBa catalysts for CO2-reforming of methane

Ni–Ba catalysts supported on γ-Al₂O₃ for the dry reforming of methane were prepared, characterized and studied under reaction conditions. Ba incorporation inhibits the formation of Ni spinel. All the Ni–Ba catalysts studied are highly active for the CO₂-reforming of methane. However, the Ni–Ba catalyst with high Ba and Ni content was the most active and stable catalyst, due to the presence of accessible Ni particles stabilized by the formation of BaAl₂O₄.     

Catalytic combustion of natural gas as the role of on-site heat supply in rapid catalytic CO2---H2O reforming of methane

Development in highly active catalysts for the reforming of methane with H₂O, CO₂, and H₂O+CO₂, and partial oxidation of methane was conducted to produce hydrogen with high reaction rates. A Ni-based three-component catalyst such as Ni---La₂O₃---Ru or Ni---Ce₂O₃---Pt supported on alumina wash-coated ceramic fiber in a plate shape was very suitable for both reactions. The catalyst composition was set at 10 wt.-% Ni, 5.6 wt.-% La₂0₃, and 0.57 wt.-% Ru for example, or molar ratios of these components were 1:0.2:0.03. Even with such a low concentration, the precious metal enhanced the reaction rate markedly, and this synergistic effect was ascribed to the hydrogen spillover effect through the part of precious metal and it resulted in a more reduced surface of the main catalyst component. In particular, a marked enhancement in the reaction rate of CO₂-reforming of methane was observed by the modification of a low concentration Rh to the Ni---Ce₂0₃---Pt catalyst. Very high space-time yields of H₂ (i.e., 8300 mol/1 h in partial oxidation of methane at 600°C with a methane conversion of 37.5%, and 3585 mol/1 h in CO₂reforming of methane at 600°C with a methane conversion of 58%) were realized in those reactions. By combining the catalytic combustion reaction, methane conversion to syngas was markedly enhanced, and even with a very short contact time (10 ms) the conversion of methane increased more than that at 50 ms. The space-time yield of hydrogen amounted to 2,780 mol/1 h with a methane conversion of 90% at 700°C. Furthermore, in a reaction of CH₄---CO₂---H₂O---O₂ on the four components catalyst, an extraordinarily high space-time yield of hydrogen, 12 190 mol/1 h, could be realized under the conditions of very high space velocity (5 ms).     

Tri-reforming of CH4 using CO2 for production of synthesis gas to dimethyl ether

In general, there are three processes for production of synthesis gas; steam reforming, CO₂ reforming and partial oxidation of methane or natural gas. In the present work, we refer to tri-reforming of methane to synthesize syngas with desirable H₂/CO ratios by simultaneous oxy-CO₂-steam reforming of methane. In this study, we report the results obtained on tri-reforming of methane over the Ni/ZrO₂ based catalyst in order to restrain the carbon deposition and to evaluate the catalytic performance. Results of tri-reforming of CH₄ by three catalysts (Ni/Ce–ZrO₂, Ni/ZrO₂ and Haldor Topsoe R67-7H) are showed that the coke on the reactor wall and the surface of catalyst were reduced dramatically. It was found that the weak acidic site, basic site and redox ability of Ce–ZrO₂ play an important role in tri-reforming of methane conversion. Carbon deposition depends not only on the nature of support, but also on the oxidant as like steam or oxygen. Therefore, the process optimization by reactant ratios is important to manufacture the synthesis gas from natural gas and carbon dioxide.     

Development of ultra-stable Ni catalysts for CO2 reforming of methane

Carbon deposition behavior in CO₂ reforming of methane, methane decomposition, and CO disproportionation on nickel-magnesia solid solution was investigated by means of thermogravimetric analysis and temperature programmed reaction of deposited carbon with carbon dioxide. It was found that rapid oxidation of CH_x on Ni surface by oxygen species from CO₂ through dissociation at metal-support interface is a key step for the inhibition of carbon formation.