Oxygen selective ceramic hollow fiber membranes for partial oxidation of methane

A BaCo_xFe_yZr_zO_3?δ (BCFZ) perovskite hollow fiber membrane was used to construct reactors for the partial oxidation of methane (POM) to syngas. The performance of the BCFZ fibers in the POM was studied (i) without any catalyst, (ii) with catalyst‐coated fibers, and (iii) with catalyst packed around the fibers. In addition to the performance in the POM, the stability of the BCFZ hollow fiber membranes was investigated for the different catalyst arrangements. Best stability of the BCFZ hollow fiber membrane reactor in the POM could be obtained if the reforming catalyst is placed behind the oxygen permeation zone. It was found that a direct contact of the catalyst and the fiber must be avoided which could be achieved by coating the fiber with a gold film. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

Failure mechanisms of ceramic membrane reactors in partial oxidation of methane to synthesis gas

In the course of generating synthesis gas (H₂, CO) from methane, we have observed two types of fractures occurring on the Sr(Co, Fe)O_x-type oxygen membrane reactors. The first type occurred shortly after the reaction started and the second type often occurred days after the reaction. To determine the causes of these fractures, we have examined the starting material and fractured membranes using a combination of X-ray diffraction and thermogravimetric analyses. We found that the first type of fracture was the consequence of an oxygen gradient in the membrane, pointing from the reaction side to the air side. This causes a lattice mismatch inside the membrane, leading to fracture. The second type of fracture, however, was the result of a chemical decomposition. We found that the Sr(Co, Fe)O_x-type membrane had been reduced to SrCO₃, and elemental Co and Fe by the synthesis gas generated in the reaction. The decomposition causes enormous expansion leading to a large crack along the axis of tube.     

SrFe0.6Cu0.3Ti0.1O3-δ透氧膜反应器中甲烷部分氧化反应工艺及膜稳定性考察

采用SrFe_0.6Cu_0.3Ti_0.1O_3-δ混合导体透氧膜组装成膜催化反应器,进行甲烷部分氧化制合成气反应,考察了反应温度、空速、催化剂粒径等条件的影响,并分析了反应气氛引起的透氧膜结构变化情况。结果表明,在膜反应器内,催化反应与透氧过程存在相互制约和相互促进的关系。在膜反应器内进行甲烷部分氧化反应后,透氧膜的两侧表面均发生蚀刻现象,结晶度显著降低,反应侧蚀刻现象较为严重,膜表面形成了疏松的多孔层,反应气氛使膜表面晶体结构发生了较大改变,Sr容易从钙钛矿结构中析出并与CO₂结合形成SrCO₃,Sr的析出导致组成不平衡,促进了钙钛矿结构分解及其他物相的产生。     

Improving selectivity during methane partial oxidation by use of a membrane reactor

A reactant-swept catalytic membrane reactor for partial oxidation of methane to formaldehyde has been modeled. Kinetic parameters were taken from the literature for a V₂O₅/Sio₂ methane partial oxidation catalyst, and membrane parameters characteristic of commercially available materials were used. The models show that the selectivity for formaldehyde can be significantly improved by using a membrane reactor.     

甲烷常压非催化部分氧化制合成气研究

考察了常压下甲烷非催化部分氧化制合成气过程中,甲烷转化率、气体产物产率以及积炭率随反应器温度、进气配比、原料气流量变化的影响。通过考察反应器温度对制备合成气过程的影响结果,分析了甲烷非催化部分氧化制合成气过程的反应机理。     

基于Ba-Ce-Co-Fe-O膜反应器的甲烷部分氧化反应研究

为开发稳定性和透氧量俱佳并适用于甲烷部分氧化反应(POM)的透氧膜材料,采用溶胶凝胶工艺合成了具有纯相钙钛矿结构的BaCe0.1Co0.4Fe0.5O3-δ混合导体陶瓷材料。POM操作结果表明:BaCe0.1Co0.4Fe0.5O3-δ膜反应器透氧量高于同类材料,875℃时透氧量达到了8.9 mL/(cm2.m in)。在1 000 h寿命实验中,膜反应器各项反应指标没有出现任何衰减,反应性能稳定,甲烷转化率和CO的选择性都在97%以上。SEM表征表明,反应后膜片表面微观结构的变化虽然不可避免,但是其仍然保持比较完整的结构。因此,该材料良好的透氧量和稳定性说明其具有较好的应用前景。     

Innovative steam methane reforming for coproducing CO-free hydrogen and syngas in proton conducting membrane reactor

Steam methane reforming (SMR) is a commercial process to produce syngas. Normally, the as-produced syngas is characterized by a H₂/CO ratio of 3. However, such H₂/CO ratio is unsuitable for Fischer–Tropsch synthesis. The hydrogen obtained by subsequent upgrading of syngas usually contains residual CO, which readily deactivates Pt electrocatalysts in fuel cells. Here we report an innovative route by coupling SMR with H₂ removal in a proton conducting membrane reactor to coproduce syngas with a preferable H₂/CO ratio of 2 and CO-free H₂ on opposite sides of the membrane, which can be directly used for Fischer–Tropsch synthesis and fuel cells, respectively. Notably, H₂ is in-situ extracted by the membrane that only allows the permeation of H₂ as protons through the oxide lattice with infinite selectivity, and thus the obtained H₂ is CO-free. This work could provide an alternative option in one-step conversion of methane into two inherently separated valuable chemicals.     

Catalytic partial oxidation of methane to synthesis gas in a ceramic membrane reactor

Methane has been selectively converted to synthesis gas using a two-zone fixed bed of a Ni/Al₂O₃ catalyst inside a modified ceramic membrane. The first zone of the reactor was surrounded by an impervious wall, and therefore behaved as a conventional fixed bed reactor. In the second zone, some of the reaction products could preferentially diffuse out of the reactor, which yielded higher than equilibrium methane conversions. The influence of the different operating conditions has been studied, and the performance of the membrane reactor has been compared to that of a fixed bed reactor. The membrane reactor has also been used at pressures above atmospheric (2 bar), with good conversions and selectivities.     

LiLaNiOx/γ-Al2O3催化剂上甲烷加压部分氧化制合成气

考察LiLaNiO_x/γ—Al_2O_3催化剂对甲烷加压[(0.2～1.0)MPa]部分氧化制合成气反应的催化性能。结果表明,LiLaNiO_x/γ—Al_2O_3催化剂具有优良的甲烷部分氧化催化性能,在850℃和1.0 MPa条件下,甲烷转化率和CO选择性分别达76.2%和82.5%。在100 h连续实验中,反应活性及选择性保持不变,显示出较高的催化稳定性。采用XRD、XPS和TG—DTA方法对反应前后催化剂的晶体结构、表面性能以及抗积炭性能进行表征,结果表明,LiLaNiO_x/γ-Al_2O_3催化剂具有较高的结构稳定性和抗积炭性能。     

Partial oxidation of methane to syngas in BaCe0.15Fe0.85O3−δ membrane reactors

Dense planar Ba_0.15Ce_0.85FeO_3−δ (BCF1585) membrane reactors were investigated to produce syngas from methane. Firstly, the membrane itself catalytic activity to methane was investigated using a blank BCF1585 without any catalysts. Then a LiLaNi/γ-Al₂O₃ catalyst was packed on the BCF1585 membrane surface to test the synergetic effects of the membrane and catalyst. It was found that the membrane itself has a poor catalytic activity to methane. The main products are CO₂ and C₂, and methane conversion is low due to the low oxygen permeation flux. However, after the catalyst was packed on the membrane surface, both methane conversion and oxygen permeation flux were greatly improved by the synergetic effect between the membrane and catalyst. Carbon monoxide selectivity reached at 96% with methane conversion of up to 96%. The oxygen permeation flux reached at 3.0 mL/cm² min at 850 °C for a 1.5 mm disk membrane and can effectively be increased by reducing the thickness of the membranes. After operation for 140 h at 850 °C, the used membrane was examined with SEM and EDXS. The results revealed that the decomposition of the membrane materials could not be avoided under such conditions. Oxygen partial pressure gradient across the membranes is suggested as a critical factor to accelerate the kinetic decomposition of the materials.     

天然气甲烷部分氧化制合成气的研究进展

甲烷部分氧化制合成气是高转化率、高选择性、高空速、低H2/CO、温和的放热反应,综述了近几年来甲烷部分氧化制合成气的催化剂、反应机理及活性中心的研究进展及反应中的存在问题。     

Partial oxidation of methane to syngas over Ni/MgO, Ni/CaO and Ni/CeO2

Partial oxidation of methane to syngas at atmospheric pressure and 750°C was examined over Ni/MgO, Ni/CaO and Ni/CeO₂ catalysts with nickel loading of 13 wt%. All catalysts had similar high conversion of methane and high selectivity to syngas, which nearly approached the values predicted by thermodynamic equilibrium. However, only Ni/MgO showed high resistance to carbon deposition under thermodynamically severe conditions (CH₄/O₂ = 2.5, a higher CH₄ to O₂ ratio than the stoichiometric ratio). Its catalytic activity remained stable during 100 h of reaction, with no detectable carbon deposition. The oxidation of carbon deposited from pure CH₄ decomposition and from pure CO disproportionation was investigated by in situ TPO-MS study which showed that both were effectively inhibited over Ni/MgO. In addition, the catalysts were characterized by TPR, XRD and XPS. It was revealed that the excellent performance of Ni/MgO resulted from the formation of an ideal solid solution between NiO and MgO. This revised version was published online in August 2006 with corrections to the Cover Date.     

钙钛矿型透氧膜及其在甲烷部分氧化中的应用

钙钛矿型透氧陶瓷膜是同时具有氧离子和电子导电性的功能无机膜,在纯氧分离和甲烷部分氧化膜反应器中具有重要的潜在应用.介绍了钙钛矿型透氧陶瓷膜的氧渗透原理、膜材料的结构性能及其在甲烷部分氧化制合成气中的应用研究进展,并对透氧膜所面临的挑战进行了论述.     

Simulations of the effect of hydrodynamic conditions and properties of membranes on the catalytic performance of a fluidized-bed membrane reactor for partial oxidation of methane

In a fluidized-bed membrane reactor the selectivity of separation can be controlled by influencing the hydrodynamics of the fluidized bed. In this reactor type, with the mass transport limitation between bubbles and the emulsion phase, even with the non-selective membranes, high selectivity of separation can be achieved. This opens the possibility for applications of membrane reactors for reaction systems for which selective membranes do not exist, e.g. when Knudsen-type membranes or form-selective separation can not be applied. This paper is aimed at explaining the interaction between the selectivity of separation and the hydrodynamics of the fluidized bed by means of simulations that were performed for a fluidized-bed membrane reactor for catalytic partial oxidation of methane.     

国内外甲烷催化部分氧化技术进展

介绍了国内外甲烷催化部分氧化制合成气技术的研究进展。主要工艺包括固定床工艺、流化床工艺和陶瓷膜工艺。此外，在反应器方面，还对两项最新专利技术进行了讨论。最后，提出了甲烷催化部分氧化制合成气技术的发展趋势，为我国在天然气利用方面的技术开发提供了参考和依据。     

Fuel processor based on syngas production via short contact time catalytic partial oxidation reactors

Short contact time catalytic partial oxidation (SCT-CPO) of natural gas is a promising technology for syngas production, representing an appealing alternative to existing processes. The high conversion and selectivity observed since the earlier works in this field can make this process attractive. Moreover, the SCT-CPO reactors can be autothermally operated and the possibility to use air as oxidant appears a feasible route to reduce syngas production costs: these two issues make possible the use of a SCT-CPO reactor as the reformer of a fuel processor for H₂ production for fuel cells.

The present work refers to an experimental study of syngas production from CH₄ and O₂ via a SCT-CPO reactor made of a fixed bed of Rh/-Al₂O₃ spheres. The main obtained results are: (i) an increase in GHSV produces an enhancement of transport rates and this in turn determines an improvement in CH₄ conversion, despite the reduction in residence time; (ii) the catalyst pellets get hotter than the gas phase thus favouring the H₂ and CO production; syngas formation is in fact both thermodynamically and kinetically promoted at high temperatures; (iii) a similar improvement of conversion was obtained with a reduction of the catalyst particle size, thanks once again to an increase in the heat transport and a higher geometrical surface area of the catalyst itself. By a slight increase of the O₂ fed to the reactor, H₂ and CO yields can be maximised and a complete CH₄ conversion achieved.     

Mechanism of the partial oxidation of methane to synthesis gas over Pd

The partial oxidation of methane to synthesis gas has been studied in an isothermal continuous flow reactor operated with the phases in plug flow, using a silica-supported palladium catalyst. The reaction mechanism involves the sequential combustion and reforming of methane. The catalyst bed is not uniform in terms of the composition of the palladium phase. The implications for investigations using a pulse apparatus are discussed. Finally, large palladium crystallites readily grow carbon filaments. This revised version was published online in July 2006 with corrections to the Cover Date.     

Effects of MgO promoter on properties of Ni/Al2O3 catalysts for partial oxidation of methane to syngas

The effects of MgO promoter on the physicochemical properties and catalytic performance of Ni/Al₂O₃ catalysts for the partial oxidation of methane to syngas were studied by means of BET, XRD, H₂-TPR, TEM and performance evaluation. It was found that the MgO promoter benefited from the uniformity of nickel species in the catalysts, inhibited the formation of NiAl₂O₄ spinel and improved the interaction between nickel species and support. These results were related to the formation of NiO-MgO solid solution and MgAl₂O₄ spinel. Moreover, for the catalysts with a proper amount of MgO promoter, the nickel dispersiveness was enhanced, therefore making their catalytic performance in methane partial oxidation improved. However, the excessive MgO promoter exerted a negative effect on the catalytic performance. Meanwhile, the basicity of MgO promoted the reversed water-gas shift reaction, which led to an increase in CO selectivity and a decrease in H₂ selectivity. The suitable content of MgO promoter in Ni/Al₂O₃ catalyst was ∼7 wt-%. Translated from Journal of Fuel Chemistry and Technology, 2006, 34(4): 450–455 [译自: 燃料化学学报]     

Development of a dual functional structured catalyst for partial oxidation of methane to syngas

Rh-LaCoO₃ structured catalysts for the oxidative production of syngas from methane were developed by deposition of the active components on La-γ-Al₂O₃ washcoated honeycomb monoliths. SEM/EDS analysis showed a good adhesion of the washcoat layer and a uniform distribution of La and Co, while Rh was favourably located on the outer shell. Catalytic partial oxidation of methane was tested under both isothermal and pseudo-adiabatic conditions showing that the process can be conducted with high yield and selectivity and stable performance at short contact times over the novel catalysts, characterised by a limited content of noble metal and no need for pre-reduction. Further experiments of CO₂ autothermal reforming indicated the possibility to enhance CO production and to reduce the H₂/CO ratio through secondary endothermic reactions consuming CO₂, which are autothermally self-sustained in a single catalytic reactor operated at short contact time by the heat generated through partial oxidation reactions.     

Ni/Si3N4催化剂在甲烷部分氧化反应中的应用

前期工作表明Ni/Si₃N₄催化剂在甲烷部分氧化反应中有较好的催化活性和很强的抗积炭能力。在前期工作的基础上考察了镍负载量和焙烧温度对Ni/Si₃N₄催化剂在甲烷部分氧化中催化性能的影响,并采用XRD、TPR、XPS等技术对催化剂进行了表征。结果表明,镍负载量和焙烧温度影响催化剂活性组分的表面分布和晶粒尺寸,并进一步影响催化剂的反应性能。在800℃反应条件下,活性组分负载量与CH₄转化率之间的关系为：C-10>C-15>C-5>C-1;而焙烧温度与CH₄转化率大小顺序为：S(400)> S(600)>S(800)。