Enthalpy recovery of gases issued from H2 production processes: Activity and stability of oxide and noble metal catalysts in oxidation reaction under highly severe conditions

Oxidation activity and stability under reaction was investigated for a series of mixed oxide catalysts, doped or not by a precious metal (Pd, Pt). The reaction feedstock, containing CO, H₂, CH₄, CO₂ and H₂O, simulated gases issued from H₂ production processes for fuel cells. Contrarily to conventional noble metal catalysts, mixed oxide samples present generally good stability under reaction at high temperature. The activities measured for the perovskite and hexaaluminate catalysts, are however largely lower than that of the reference Pd/Al₂O₃ catalyst. High activities were obtained after impregnation of 1.1 wt.% Pd or 0.8 wt.% Pt on the hexaaluminates samples. Even if Pd/Al₂O₃ was found to present a high activity, this sample suffered from drastic deactivation at 700 °C. Better stability were obtained on perovskite. Furthermore, doping hexaaluminate by Pt led to samples with good activities and high stability. Even if better activities were obtained by doping the hexaaluminate samples by Pd, the Pd/BaAl₁₂O₁₉ strongly deactivated, as it was previously observed for the reference catalyst. Interestingly, this Pd deactivation was not observed when Pd was impregnated on the Mn substituted hexaaluminate, leading to a stable and active catalyst. This suggests that it is possible to stabilize the palladium in its oxidized form at high temperature (700 °C) on the surface of some supports.     

Application of Ce0.33Zr0.63Pr0.04O2-supported noble metal catalysts in the catalytic wet air oxidation of 2-chlorophenol: Influence of the reaction conditions

In this work, different procedures, namely carbonate coprecipitation and modified solid–solid diffusion, were used to prepare hexaaluminate samples, unsupported or supported onto θ-Al₂O₃. These samples were used as catalyst for the methane total oxidation as synthesized or after impregnation of 1 wt% Pd. It was observed that the modified solid–solid diffusion procedure is an efficient method to obtain the hexaaluminate structure. At a theoretical ratio x of hexaaluminate onto Al₂O₃ less than 0.6 (xLa_0.2Sr_0.3Ba_0.5MnAl₁₁O₁₉ + (1−x)·Al₂O₃, with x = 0.25, 0.60), samples with high specific surface area and θ-Al₂O₃ structure are then obtained. Large differences in catalytic activity can be observed among the series of sample synthesized. All the pure oxide samples (i.e. without palladium) present low catalytic activity for methane total oxidation compared to a reference Pd/Al₂O₃ catalyst. The highest activity was obtained for the samples presenting a θ-Al₂O₃ structure (with x = 0.60) and a high surface area. Impregnation of 1 wt% palladium resulted in an increase in catalytic activity, for all the solids synthesized in this work. Even if the lowest light-off temperature was obtained on the reference sample, similar methane conversions at high temperature (700 °C) were obtained on the stabilized θ-Al₂O₃ solids (x = 0.25, 0.60). Moreover, the reference sample is found to strongly deactivate with reaction time at the temperature of test (700 °C), due to a progressive reduction of the PdO_x active phase into the less active Pd° phase, whereas excellent stabilities in reaction were obtained on the pure and palladium-doped hexaaluminate and supported θ-Al₂O₃ samples. This clearly showed the beneficial effect of the support for the stabilization of the PdO_x active phase at high reaction temperature. These properties are discussed in term of oxygen transfer from the support to the palladium particle. Oxygen transfer is directly related to the Mn³⁺/Mn²⁺ redox properties (in the case of the hexaaluminate and stabilized θ-Al₂O₃ samples), that allows a fast reoxidation of the metal palladium sites since palladium sites reoxidation cannot occur directly by gaseous dioxygen adsorption and dissociation on the surface.     

Effect of Pd precursor salt on the activity and stability of Pd-doped hexaaluminate catalysts for the CH4 catalytic combustion

This study reports the influence of palladium salt precursor on the catalytic activity of palladium-doped hexaaluminate catalysts for the combustion of 1 vol% CH₄ in the presence of CO₂ and H₂O as inhibitors. Thermal stability of the catalysts is evaluated in long-term catalytic test at 700 °C. The hexaaluminate supports were synthesized using two different procedures: conventional coprecipitation and solid/solid diffusion procedure. Palladium impregnation was carried out by two different routes using Pd(NO₃)₂ in water or Pd(acac)₂ in toluene as impregnation solution. It was observed that using Pd(acac)₂ as precursor allows to attain higher dispersion of the active phase (Pd particles size <3 nm). Compared to the catalysts obtained by impregnation of Pd(NO₃)₂, higher catalytic activities are then obtained. Nevertheless, a deactivation of the samples obtained using Pd(acac)₂ is observed. At the end of the stability test, almost similar catalytic activity is obtained whatever the palladium precursor. Reduction–reoxidation experiment showed that this deactivation is irreversible, and TEM analysis suggest that this deactivation is related to the sintering of Pd particles under reaction over samples synthesized using Pd(acac)₂ as precursor.     

Surfactant-mediated synthesis of metal substituted hexaaluminate from alumina sol

Manganese substituted hexaaluminate has been prepared using environmentally benign surfactants such as Triton X-100, under ambient condition with a commercial alumina sol and metal acetate precursors. The surface area of the pure alumina can be controlled to 10–70 m² g⁻¹ using cetyltrimethylammonium chloride after heating in oxygen flow at 1200°C for 6 h. The crystal structure of the obtained alumina was high purity θ-Al₂O₃. Incorporation of La and Mn leads to the formation of the high purity manganese substituted hexaaluminate with a surface area of 30–40 m² g⁻¹ which is also controllable using organic additives such as urea. The catalytic activity of the manganese substituted hexaaluminate was comparable to the sol–gel derived hexaaluminate catalyst from metal alkoxides.     

Pd–Ce interactions and adsorption properties of palladium: CO and NO TPD studies over Pd–Ce/Al2O3 catalysts

We have examined the adsorption of CO and NO on powder Pd/Al₂O₃, Pd–Ce/Al₂O₃ and CeO₂/Al₂O₃ catalysts, using temperature-programmed desorption (TPD). For CO adsorption on oxidized and pre-reduced Pd–Ce/Al₂O₃ TPD profiles are identical to those observed for Pd/Al₂O₃, suggesting that interactions between ceria and Pd have a negligible effect on the adsorption properties of CO. It does, however, affect the oxidation state of the palladium particles. For NO, there are differences between Pd/Al₂O₃ and Pd–Ce/Al₂O₃. On oxidized catalysts, Pd/Al₂O₃ is more efficient for NO dissociation. However, pre-reduction increases the amount of NO that can adsorb on Pd–Ce/Al₂O₃ and react to N₂O and N₂. In comparison with Pd/Al₂O₃, reduced Pd–Ce/Al₂O₃catalysts dissociate NO at relatively high temperatures but they are more reactive and favor N₂ over N₂O.     

Oxidation of methane over Pd/mixed oxides for catalytic combustion

Palladium catalysts supported on mixed oxides (Pd/Al₂O₃–MO_x; M=Co, Cr, Cu, Fe, Mn, and Ni) were investigated for the low-temperature catalytic combustion of methane. Although the surface area decreased with increasing NiO in Pd/mAl₂O₃–nNiO, Pd/Al₂O₃–36NiO demonstrated an excellent activity due to the small particle size of palladium. Also, the catalytic activity strongly depended on the composition of the support. Temperature-programmed desorption of oxygen revealed that the catalytic activity in the low-temperature region depends on the adsorption state of oxygen on palladium. The activity was enhanced when the amount of adsorbed oxygen increased. In-situ XRD analysis indicated that the PdO phase was thermally stabilized on Pd/Al₂O₃–36NiO.     

Characterization and catalytic activity of Pd/V2O5/Al2O3 catalysts on benzene total oxidation

The role of vanadium oxide and palladium on the benzene oxidation reaction over Pd/V₂O₅/Al₂O₃ catalysts was investigated. The Pd/V₂O₅/Al₂O₃ catalysts were more active than V₂O₅/Al₂O₃ and Pd/Al₂O₃ catalysts. The increase of vanadium oxide content decreased the Pd dispersion and increased the benzene conversion. A strong Pd particle size effect on benzene oxidation reaction was observed. Although the catalysts containing high amount of V⁴⁺ species were more active, the Pd particle size effect was responsible for the higher activity.     

CO2 hydrogenation over Pd-modified methanol synthesis catalysts

The effect of palladium incorporation on the performance of Cu–ZnO(Al₂O₃) during the hydrogenation of carbon dioxide has been assessed. Temperature-programmed reduction profiles and X-ray photoelectron spectra of copper revealed that Pd enhances copper oxide reduction. Carbon dioxide conversion and methanol yield were found to increase on Pd-loaded catalysts. The importance of the palladium incorporated to the base Cu–ZnO(Al₂O₃) catalyst in determining the catalytic activity is discussed in terms of the relative ease with which hydrogen is dissociated on the Pd particles and then spilt over the Cu–ZnO phase of the base catalyst.     

Degradation mechanisms of magnesia-chromite refractories by high-alumina stainless steel slags under vacuum conditions

The corrosion behaviour of magnesia-chromite refractory by an alumina-rich (15–20 wt.%) stainless steelmaking slag is investigated by rotating finger tests in a vacuum induction furnace. The influence on the refractory wear, of the process temperature, corrosion time and, in particular, the high Al₂O₃ content in the slag, is discussed. Two distinct mechanisms cause primary chromite degradation: FeO_x and Cr₂O₃ decomposition because of low oxygen potentials and dissolution by infiltrated slag due to the high Al₂O₃ slag content. Upon decomposition, small metallic particles and pores are homogeneously generated inside the primary chromite. At the refractory/slag interface, a relatively continuous solid (Mg,Mn)[Al,Cr]₂O₄ spinel layer is formed. Its density and stability decreases with higher temperatures and more turbulent conditions. The spinel formation arises through heterogeneous in situ precipitation from a slag rich in spinel forming compounds. Higher Al₂O₃ levels in the slag promote the spinel layer formation, which may limit slag infiltration. Finally, it is shown that the present experimental procedure is an excellent tool to simulate refractory wear in industrial processes, diminishing the risks associated with plant trials.     

Palladium–vanadium interaction in binary supported catalysts

We have studied the activity and selectivity of Pd/γ-Al₂O₃, VO_x/γ-Al₂O₃ and Pd–VO_x/γ-Al₂O₃ catalysts for the decomposition of NO and the reduction of NO with CO. Pd–VO_x/γ-Al₂O₃ catalysts were prepared by anchoring Pd(AcAc)₂ on VO_x/γ-Al₂O₃. Characterization of the binary samples by hydrogen chemisorption and TPR measurements indicated that the reduction of VO_x is enhanced by a close contact with palladium and that partially reduced vanadia decorate noble metal particles. This palladium–vanadium interaction alters the catalytic properties of palladium: the activity for NO decomposition is higher for the binary sample and, for the NO–CO reaction, both the activity and the selectivity to N₂ increase when vanadium is in contact with palladium.     

Effect of pH in a sol–gel synthesis on the physicochemical properties of Pd–alumina three-way catalyst

The effect of pH during sol–gel synthesis on the structural and physicochemical properties of a Pd–Al₂O₃ three-way catalyst (TWC) prepared by the sol–gel method was investigated by using BET, X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), transmission electron microscopy (TEM) and solid state ²⁷Al MAS NMR. The Pd–Al₂O₃ catalyst prepared at pH=10 (Pd–Al₂O₃–B) showed a high activity in three-way catalytic reaction, a high dispersion of Pd, and large surface area and pore volume. A basic condition (pH=10) in the sol–gel process was essential for the preparation of highly dispersed palladium clusters on alumina gel. The formation of highly stable palladium oxide species in Pd–Al₂O₃–B that were not completely reduced at 423 K was ascribed to the strong interaction between Pd and oxygen in alumina texture, resulting in the formation of –Al–O–Pd bond.     

Cu-based spinel catalysts CuB2O4 (B = Fe, Mn, Cr, Ga, Al, Fe0.75Mn0.25) for steam reforming of dimethyl ether

Cu-based spinel-oxides CuB₂O₄ (B = Fe, Mn, Cr, Ga, Al, or Fe_0.75Mn_0.25) were synthesized via a sol–gel method and subsequent solid-state reaction. The spinels mechanically mixed with γ-Al₂O₃ were evaluated for production of hydrogen from dimethyl ether steam reforming (DME SR). The reduction behavior and crystal property of these spinel-oxides, and the Cu oxidation state in spinel catalysts were investigated by temperature-programmed reduction, X-ray diffraction, and X-ray photoelectron spectroscopy techniques. The reduced phases of the Cu-based spinel catalysts that strongly affected the catalytic activity and durability were composed of metallic copper with metal oxides (MnO (B = Mn), Cr₂O₃ (B = Cr), and Al₂O₃ (B = Al)) or with spinels (CuGa₂O₄ (B = Ga), Fe₃O₄ (B = Fe), and MnFe₂O₄ (B = Fe_0.75Mn_0.25). The stability of B metal oxides and the interaction between copper species and B metal oxides significantly contributed to the reforming performance.     

Synthesis of CeO2–MnOx mixed oxides and catalytic performance under oxygen-rich condition

Ce_0.5Zr_0.5O₂, Ce_0.5Zr_0.2Mn_0.3O₂ and Ce_0.5Mn_0.5O₂ were prepared by citric acid sol–gel method. The effect of manganese on the structural and redox properties of ceria-based mixed oxides was investigated by means of powder X-ray diffraction, X-ray photoelectron spectroscopy, Brunauer–Emmett–Teller analyses, temperature-programmed reduction and catalytic activity evaluation in the presence of excess O₂. The results showed that some Mn cations could enter into the ceria lattice to form solid solutions. Mn₃O₄ appeared due to the instability of the mixed oxides with increment of the Mn doping ratio while another oxide Mn₂O₃ is detected in the physical mixture of ceria and manganese oxide. These Mn-doped mixed oxides, especially Ce_0.5Mn_0.5O₂, presented better catalytic activities than Ce_0.5Zr_0.5O₂ and even Pt-loaded catalyst for total oxidation of C₃H₈ and oxidative sorption of NO in the presence of excess oxygen. The oxidation ability of Mn and the strong interaction between Mn and Ce were suggested to promote the oxygen storage/transport capacity of the mixed oxides as well as reactive adsorption of nitric oxide and hydrocarbons.     

Sol–gel preparation of cobalt manganese mixed oxides for their use as electrode materials in lithium cells

An ethanol dehydration procedure has been used to precipitate gel-like citrate precursors containing cobalt and manganese transition metal ions. Further annealing led to the Mn_xCo_3−xO₄ spinel oxide series (x: 1, 1.5, 2, 3). Annealing temperature and treatment time were also evaluated to optimize the performance of the oxides as active electrode materials in lithium cells. The manganese–cobalt mixed oxides obtained by this procedure were cubic or tetragonal phases depending on the cobalt content. SEM images showed spherical macroporous aggregates for MnCo₂O₄ and hollow spheres for manganese oxides. The galvanostatic cycling of lithium cells assembled with these materials demonstrated a simultaneous reduction of cobalt and manganese during the first discharge and separation of cobalt- and manganese-based products on further cycling. As compared with binary manganese oxides, a notorious electrochemical improvement was observed in the mixed oxides. This behavior is a consequence of the synergistic effect of both transition metal elements, associated with the in-situ formation of a nanocomposite electrode material when cobalt is introduced in the manganese oxide composition. Values higher than 400 mAh/g were sustained after 50 cycles for MnCo₂O₄.     

Catalytic purification of flue gas from civil-used stove

Effects of the method of burning and addition of catalysts in the chimney of civil-used stove on emission of air pollutants were studied. Alumina-supported copper and manganese oxides and palladium catalysts were used to purify the flue gas emitted from the civil-used stoves. The results show that, in upper burning case, both Cu–Mn–O/Al₂O₃ and Pd/CuO/Al₂O₃ catalysts can decrease the ratio of CO/CO₂ to <0.01, and remove SO₂ and volatile organic chemicals (VOC) from the flue gas to some extent. Deactivation of the catalyst results from the accumulation of sulfate groups on catalyst support. The life of the catalyst can be extended by adding a honeycomb of lime before the catalyst.     

Catalytic combustion of methane in non-permselective membrane reactors with separate reactant feeds

Catalytic combustion of methane over Pd and Pt/SiO₂/-Al₂O₃ membranes was studied in the temperature range 300–650 °C. Fuel and oxygen were fed at opposite membrane sides. In order to improve reactor controllability the -Al₂O₃ membranes were impregnated with SiO₂ sol resulting to smaller pore size. Methane conversions up to 100% for the palladium membrane and up to 42% for the platinum membrane were achieved. The results indicated a transition from kinetic to mass transfer control within the temperature range investigated. This was accompanied by reduction of methane slip from tube to shell side with increasing temperature. CO and H₂ were detected in the product gases of the palladium membrane. Their concentration could be reduced by applying a trans-membrane pressure difference. Low concentrations of CO were observed for the Pt/SiO₂/-Al₂O₃ membrane, while no CO or H₂ were detected for a Pd/-Al₂O₃ membrane operating in dead-end configuration.     

Total oxidation catalysts based on manganese or copper oxides and platinum or palladium I: Characterisation

Temperature-programmed reduction (TPR), oxidation (TPO), Raman spectroscopy, X-ray photoelectron spectroscopy (XPS) and X-ray diffraction (XRD) were used to characterise catalysts based on manganese oxides, copper oxides or one of them mixed with platinum or palladium-supported on γ-alumina. The catalysts were characterised before and after they had been exposed either to high temperature in the presence of steam or to sulphur dioxide. Raman spectroscopy, XRD, XPS and TPR performed on the fresh samples of MnO_x, mixed MnO_x–Pt and MnO_x–Pd revealed the presence of a mixture of manganese oxides, particularly Mn₂O₃. In the fresh mixed MnO_x–Pd and CuO_x–Pd samples, Pd catalysed the reduction of both MnO_x and CuO_x, whereas Pt only catalysed the reduction of MnO_x. After hydrothermal treatment at 900°C of the MnO_x, mixed MnO_x–Pt and MnO_x–Pd samples, there was a formation of new manganese oxide phase, Mn₃O₄ detected by Raman spectroscopy. TPR revealed increasing interaction between the metal oxides and the noble metals in the hydrothermally treated mixed MnO_x–Pd and CuO_x–Pd samples, and also the appearance of interaction in the treated mixed CuO_x–Pt sample. The sulphur adsorbed in all the MnO_x samples formed sulphate, which was more difficult to reduce than the oxides. Also, the reduction temperature of sulphates was lowered when noble metals are present.     

Dependence of Synergetic Effect of Palladium–Manganese-Hexaaluminate Combustion Catalyst on Nature of Palladium Precursor

A synergetic effect in the methane oxidation activity of palladium and manganese hexaaluminate was studied over Pd-modified manganese-hexaaluminate catalysts, prepared by incipient wetness impregnation and calcined at 1,200?°C. The magnitude of the synergetic effect is found to be depends on the palladium precursor: it is higher for palladium nitrate and palladium acetate than for tetrachloropalladic acid. The Pd/MnLaAl₁₁O₁₉ catalysts were characterized by X-ray diffraction, X-ray microanalysis, transmission electron microscope and temperature-programmed reduction with hydrogen. These data were compared with the properties of Pd/Al₂O₃ catalysts. At variation of Pd-precursors, a minor trend to the decrease of the Pd particle size was observed at transition from the ex-chloride Pd/MnLaAl₁₁O₁₉ catalyst with uniform Pd-distribution profile to the ex-nitrate and ex-acetate catalysts with egg-shell Pd-distribution. Slightly smaller size of metal palladium particles in the ex-nitrate and ex-acetate catalysts leads to the formation of larger amount of PdO dispersed on their surface during oxygen-pretreatment in H₂-TPR experiments (Pd/PdO atomic ratio was 1/4) and under methane-oxidation mixture in comparison with ex-chloride catalysts (Pd/PdO?=?4/1). The palladium addition to manganese-hexaaluminate changes strongly its redox properties, as result Mn³⁺ reduction to Mn²⁺ take place about 100?°C below that of pure hexaalunimate. The latter indicate probably on the higher oxygen mobility in Pd-modified manganese-hexaaluminate. A higher PdO/Pd ratio formed in the ex-nitrate and ex-acetate Pd-modified manganese-hexaaluminate catalysts together with the high oxygen mobility provide the synergetic effect in methane oxidation activity at light-off temperature region. The high catalytic activity of manganese-hexaaluminate ensures methane combustion efficiency of the Pd-modified manganese-hexaaluminate catalysts at temperature above 700?°C.     

Performance and characterization of Ru/Al2O3 and Ru/SiO2 catalysts modified with Mn for Fischer–Tropsch synthesis

Mn effect and characterization on γ-Al₂O₃-, -Al₂O₃- and SiO₂-supported Ru catalysts were investigated for Fischer–Tropsch synthesis under pressurized conditions. In the slurry phase Fischer–Tropsch reaction, γ-Al₂O₃ catalysts showed higher performance on CO conversion and C₅⁺ selectivity than -Al₂O₃ and SiO₂ catalysts. Moreover, Ru/Mn/γ-Al₂O₃ exhibited high resistance to catalyst deactivation and other catalysts were deactivated during the reaction. From characterization results on XRD, TPR, TEM, XPS and pore distribution, Ru particles were clearly observed over the catalysts, and γ-Al₂O₃ catalysts showed a moderate pore and particle size such as 8 nm, where -Al₂O₃ and SiO₂ showed highly dispersed ruthenium particles. The addition of Mn to γ-Al₂O₃ enhanced the removal of chloride from RuCl₃, which can lead to the formation of metallic Ru with moderate particle size, which would be an active site for Fischer–Tropsch reaction. Concomitantly, manganese chloride is formed. These schemes can be assigned to the stable nature of Ru/Mn/γ-Al₂O₃ catalyst.     

Promotion of palladium-based catalysts on metal monolith for partial oxidation of methane to syngas

Four different modifications of alumina were prepared for use as the support for a Pd catalyst used for the partial oxidation of methane to syngas. The catalysts were washcoated on a metallic monolith in order to determine their activities at high gas flow rates. Compared with the Pd/Al₂O₃ catalyst, enhanced partial oxidation activities were observed with the Pd/CeO₂/Al₂O₃, Pd/CeO₂/BaO/Al₂O₃ and Pd/CeO₂/BaO/SrO/Al₂O₃ catalysts. The palladium particles were better dispersed in the presence of CeO₂ and SrO. Adding BaO, CeO₂ and BaO–CeO₂ to γ-Al₂O₃ prevented the transformation of the alumina phase during the 3-day aging process at 1000 °C, providing the support with some level of thermal stability. The addition of small amounts of SrO to the CeO₂/BaO/Al₂O₃ support enhanced the thermal stability of the Pd particles and minimized their sintering. The triply promoted Pd catalyst studied in this work was effective in carrying out partial oxidation at high temperatures, with BaO and CeO₂ promoting the thermal stability of the support, CeO₂ and SrO dispersing the Pd particles and SrO anchoring the Pd particles strongly to the support. The composition of the catalyst which gave both the highest partial oxidation activity and the best thermal stability was Pd(2)/CeO₂(23)/BaO(11)/SrO(0.8)/Al₂O₃.