Production of hydrogen by methane catalytic decomposition over Ni–Cu–Fe/Al2O3 catalyst

Catalysts with high nickel concentrations 75%Ni–12%Cu/Al₂O₃, 70%Ni–10%Cu–10%Fe/Al₂O₃ were prepared by mechanochemical activation and their catalytic properties were studied in methane decomposition. It was shown that modification of the 75%Ni–12%Cu/Al₂O₃ catalyst with iron made it possible to increase optimal operating temperatures to 700–750 °C while maintaining excellent catalyst stability. The formation of finely dispersed Ni–Cu–Fe alloy particles makes the catalysts stable and capable of operating at 700–750 °C in methane decomposition to hydrogen and carbon nanofibers. The yield of carbon nanofibers on the modified 70%Ni–10%Cu–10%Fe/Al₂O₃ catalyst at 700–750 °C was 150–160 g/g. The developed hydrogen production method is also efficient when natural gas is used as the feedstock. An installation with a rotating reactor was developed for production of hydrogen and carbon nanofibers from natural gas. It was shown that the 70%Ni–10%Cu–10%Fe/Al₂O₃ catalyst could operate in this installation for a prolonged period of time. The hydrogen concentration at the reactor outlet exceeded 70 mol%.     

Methane decomposition on Ni–Cu alloyed Raney-type catalysts

In the present work, we report on the performance of Ni–Cu alloyed Raney-type catalysts for the production of hydrogen by catalytic methane decomposition. The activity of the catalysts was assessed by comparing the experimental conversions with the calculated equilibrium conversions for each set of experimental conditions. The stability of the catalysts was assessed by comparing the maximum conversions with the conversions at the end of 5 h tests. Comparison with monometallic Ni Raney-type catalytic systems shows that Cu addition significantly improves catalyst stability. Excellent results were obtained when the Ni–Cu Raney-type system was thermally treated in situ at 600 °C, as a result of incipient alloy formation.     

CO2 dry-reforming of methane over La0.8Sr0.2Ni0.8M0.2O3 perovskite (M = Bi,Co, Cr,Cu, Fe): Roles of lattice oxygen on C–H activation and carbon suppression

La_0.8Sr_0.2Ni_0.8M_0.2O₃ (LSNMO) (where M = Bi, Co, Cr, Cu and Fe) perovskite catalyst precursors have been successfully developed for CO₂ dry-reforming of methane (DRM). Among all the catalysts, Cu-substituted Ni catalyst precursor showed the highest initial catalytic activity due to the highest amount of accessible Ni and the presence of mobile lattice oxygen species which can activate C–H bond, resulting in a significant improvement of catalytic activity even at the initial stage of reaction. However, these Ni particles can agglomerate to form bigger Ni particle size, thereby causing lower catalytic stability. As compared to Cu-substituted Ni catalyst, Fe-substituted Ni catalyst has low initial activity due to the lower reducibility of Ni–Fe and the less mobility of lattice oxygen species. However, Fe-substituted Ni catalyst showed the highest catalytic stability due to: (1) strong metal–support interaction which hinders thermal agglomeration of the Ni particles; and (2) the presence of the abundant lattice oxygen species which are not very active for C–H bond activation but active to react with CO₂ to form La₂O₂CO₃, hence minimizing carbon formation by reacting with surface carbon to form CO.     

Ni–SiO2 and Ni–Fe–SiO2 catalysts for methane decomposition to prepare hydrogen and carbon filaments

Active and stable Ni–Fe–SiO₂ catalysts prepared by sol–gel method were employed for direct decomposition of undiluted methane to produce hydrogen and carbon filaments at 823 K and 923 K. The results indicated that the lifetime of Ni–Fe–SiO₂ catalysts was much longer than Ni–SiO₂ catalyst at a higher reaction temperature such as 923 K, however, a reverse trend was shown when methane decomposition took place at a lower reaction temperature such as 823 K. XRD studies suggested that iron atoms had entered into the Ni lattice and Ni–Fe alloy was formed in Ni–Fe–SiO₂ catalysts. The structure of the carbon filaments generated over Ni–SiO₂ and Ni–Fe–SiO₂ was quite different. TEM studies showed that “multi-walled” carbon filaments were formed over 75%Ni–25%SiO₂ catalyst, while “bamboo-shaped” carbon filaments generated over 35%Ni–40%Fe–25%SiO₂ catalysts at 923 K. Raman spectra of the generated carbons demonstrated that the graphitic order of the “multi-walled” carbon filaments was lower than that of the “bamboo-shaped” carbon filaments.     

Preparation of activated carbon supported Fe–Al2O3 catalyst and its application for hydrogen production by catalytic methane decomposition

Activated carbon (AC) supported Fe–Al₂O₃ catalysts were prepared by impregnation method and used for catalytic methane decomposition to hydrogen. The XRD and H₂-TPR results showed that ferric nitrate on AC support was directly reduced to Fe metal by the reducibility of carbon at 870 °C. The loading amount and Fe/Al₂O₃ weight ratio affect the textural properties and catalytic methane decomposition. The surface area and pore volume of the catalyst decrease with the loading of Fe and Al₂O₃. Mesopores with size of about 4.5 nm can be formed at the loading of 20–60% and promote the catalytic activity and stability. The mesopores formation is thought that Fe accelerates burning off of carbon wall and enlarging pore sizes during the pretreatment. When the Fe/Al₂O₃ ratio is 16/24 to 24/16 at the loading of 40%, the resultant catalysts show narrow mesopore distributions and relative high methane conversion. Al₂O₃ as the promoter can improve catalytic activity and shorten transitional period of AC supported Fe catalyst.     

Non-thermal plasma assisted synthesis and physicochemical characterizations of Co and Cu doped Ni/Al2O3 nanocatalysts used for dry reforming of methane

Ni/Al₂O₃ nanocatalysts doped with Co and Cu were prepared by co-impregnation and modified by non-thermal plasma. The nanocatalysts were characterized by XRD, FESEM, TEM, EDX dot-mapping, BET, FTIR, TGA-DTG, and XPS analysis. According to XRD and XPS results, good interaction between active phase and support can be observed in both Ni–Co/Al₂O₃ and Ni–Cu/Al₂O₃ nanocatalysts. A uniform morphology, high surface area, and well dispersed particles of active sites in Ni–Co/Al₂O₃ nanocatalyst were observed that shows the effect of cobalt in controlling Ni ensemble size. In contrast Ni–Cu/Al₂O₃ nanocatalyst had no homogenous dispersion of active phase due to sintering of copper particles. The activity measurements illustrated better Ni–Co/Al₂O₃ nanocatalyst activity in comparison to Ni/Al₂O₃ and Ni–Cu/Al₂O₃ in terms of CH₄ and CO₂ conversion. H₂ and CO yield were higher for Ni–Co/Al₂O₃ and higher H₂/Co ratio was obtained as well. Whereas Ni/Al₂O₃ and Ni–Co/Al₂O₃ did not experience deactivation, Ni–Cu/Al₂O₃ suffered from activity loss by ca. 22% and 16% for CH₄ and CO₂ conversion, respectively. Sintering most likely happened in Ni–Cu/Al₂O₃ nanocatalyst due to high temperature of calcination while cobalt by controlling the size of Ni particles, alternated the size of active sites to a size range in which carbon formation was suppressed. Ni/Al ratio from XPS analysis which signifies Ni dispersion on alumina support was 5.15, 9.16, and 6.35 for Ni/Al₂O₃, Ni–Co/Al₂O₃, and Ni–Cu/Al₂O₃ nanocatalysts respectively. The highest ratio of Ni/Al was for Ni–Co/Al₂O₃ nanocatalyst that shows the best coverage of support by Ni active phase in this nanocatalyst.     

Development of Fe2O3–TiO2 mixed oxide incorporated Ni–P coating for electrocatalytic hydrogen evolution reaction

Considering the electronic parameters and chemical characteristics, a synergistic catalytic effect of Fe₂O₃ along with TiO₂ could be achieved for electrochemical reactions if both the oxides are produced in a mixed oxide form. The present study explored the mixed oxide composite viz; Fe₂O₃–TiO₂, synthesized via thermal decomposition method, to increase the catalytic efficiency of Ni–P electrodes, the well known catalytic electrodes for hydrogen evolution reaction in alkaline medium. The incorporation of the Fe₂O₃–TiO₂ mixed oxide into Ni–P matrix substantially reduced overpotential during hydrogen evolution reaction (HER) in 32% NaOH solution. A significant improvement on the electrochemical activity of the Ni–P coated electrodes was achieved as evidenced from the results of Tafel and impedance studies. The incorporation of Fe₂O₃–TiO₂ mixed oxide composite into the Ni–P matrix has improved both metallurgical and electrochemical characteristics and hence its amount of incorporation should be optimum. The electrodes exhibited high stability under dynamic experimental conditions. The role of the composite and the possible mechanism are discussed in this paper.     

Preparation of highly stable bimetallic Ni–Cu catalyst for simultaneous production of hydrogen and fish-bone carbon nanofibers: Optimization,effect of catalyst preparation methods and deactivation

This paper presents the preparation of highly stable nano-porous Ni–Cu catalysts for simultaneous production of CO_x–free hydrogen and carbon nano-fibers. The main features of this work focuses on the optimization, methods of catalyst preparation and application of an experimental model for deactivation. The fresh catalysts and the deposited carbon were characterized by SEM, TEM, XRD and Raman spectroscopy. Whatever to be the preparation methods, performance tests showed that the presence of Cu as promoter in Ni–Cu–MgO catalysts, enhanced the catalytic activity, substantially at higher temperatures with the best result obtained for Ni–Cu–MgO catalyst prepared by one step sol- gel method, reaching a hydrogen concentration of 70 vol% (160.51 mol H₂/mol Ni-1 h) and a smaller value of I_D/I_G (less imperfection) for produced carbon nano-fibers at 670 °C. Detailed rate-based model for deactivation of catalyst was found to be dependent on the time, reaction temperature and partial pressure of methane and indicated that the reaction of deactivation could be modeled by a simple hyperbolic model.     

A new nickel–ceria composite for direct-methane solid oxide fuel cells

Various Ni–La_xCe_1−xO_y composites were synthesized and their catalytic activity, catalytic stability and carbon deposition properties for steam reforming of methane were investigated. Among the catalysts, Ni–La_0.1Ce_0.9O_y showed the highest catalytic performance and also the best coking resistance. The Ni–La_xCe_1−xO_y catalysts with a higher Ni content were further sintered at 1400 °C and investigated as anodes of solid oxide fuel cells for operating on methane fuel. The Ni–La_0.1Ce_0.9O_y anode presented the best catalytic activity and coking resistance in the various Ni–La_xCe_1−xO_y catalysts with different ceria contents. In addition, the Ni–La_0.1Ce_0.9O_y also showed improved coking resistance over a Ni–SDC cermet anode due to its improved surface acidity. A fuel cell with a Ni–La_0.1Ce_0.9O_y anode and a catalyst yielded a peak power density of 850 mW cm⁻² at 650 °C while operating on a CH₄–H₂O gas mixture, which was only slightly lower than that obtained while operating on hydrogen fuel. No obvious carbon deposition or nickel aggregation was observed on the Ni–La_0.1Ce_0.9O_y anode after the operation on methane. Such remarkable performances suggest that nickel and La-doped CeO₂ composites are attractive anodes for direct hydrocarbon SOFCs and might also be used as catalysts for the steam reforming of hydrocarbons.     

Electrochemical performance of a copper-impregnated Ni–Ce0.8Sm0.2O1.9 anode running on methane

Ni–Cu–Ce_0.8Sm_0.2O_1.9 anode-supported single cells were developed for the direct utilization of methane. An yttria-doped zirconia and Ce_0.8Sm_0.2O_1.9 bi-layer electrolyte and a La_0.6Sr_0.4Co_0.2Fe_0.8O_3 − δ cathode layer were fabricated by slurry spin-coating. Cu was added to the anode by impregnation with a nitrate solution. The effects of Cu on the electrochemical performance of the anode were investigated in dry methane with respect to times of impregnation. Impregnation with Cu twice was determined to be optimal. Incorporating Cu into the anode improved electrochemical performance of the cells, reducing ohmic resistance and suppressing carbon deposition. At 700 °C, the single cell exhibited a maximum power density of 406 mW/cm² in dry methane. At a current density of 500 mA/cm², the cell maintained 98.6% of its initial voltage after operation for 900 min.     

High performance of Mg–La mixed oxides supported Ni catalysts for dry reforming of methane: The effect of crystal structure

A series of mixed Mg–La oxide supports with various Mg²⁺/La³⁺ mole ratios were prepared via co-precipitation of Mg and La nitrates, and then impregnated to form 5 wt.% Ni catalysts. The as-prepared catalysts were evaluated in DRM reaction for 200 h and characterized by means of in situ DRIFTS, XRD, TEM, CO₂-TPD, XPS, and TGA. It was found that the interaction of suitable amount of MgO with La₂O₃ stabilized cubic La₂O₃ species in catalysts, which has high basicity to adsorb CO₂ forming monoclinic La₂O₂CO₃ (Ia) species in DRM reaction. The introduction of MgO also created surface oxygen ions (i.e. O^–). Both monoclinic La₂O₂CO₃ (Ia) and surface oxygen species are able to oxidize and remove deposited carbon, keeping the Ni catalyst at high activity and stability. Low Mg²⁺/La³⁺ ratios generated hexagonal La₂O₃ and La₂O₂CO₃ (II) in DRM reaction. The hexagonal La₂O₂CO₃ (II) did not play significant role in carbon removal so that the catalysts deactivated fast.     

Hydrogen production by steam reforming of ethanol over mesoporous Ni–Al2O3–ZrO2 aerogel catalyst

A mesoporous Ni–Al₂O₃–ZrO₂ aerogel (Ni–AZ) catalyst was prepared by a single-step epoxide-driven sol–gel method and a subsequent supercritical CO₂ drying method. For comparison, a mesoporous Al₂O₃–ZrO₂ aerogel (AZ) support was prepared by a single-step epoxide-driven sol–gel method, and subsequently, a mesoporous Ni/Al₂O₃–ZrO₂ aerogel (Ni/AZ) catalyst was prepared by an incipient wetness impregnation method. The effect of preparation method on the physicochemical properties and catalytic activities of Ni–AZ and Ni/AZ catalysts was investigated. Although both catalysts retained a mesoporous structure, Ni/AZ catalyst showed lower surface area than Ni–AZ catalyst. From TPR, XRD, and H₂–TPD results, it was revealed that Ni–AZ catalyst retained higher reducibility and higher nickel dispersion than Ni/AZ catalyst. In the hydrogen production by steam reforming of ethanol, both catalysts showed a stable catalytic performance with complete conversion of ethanol. However, Ni–AZ catalyst showed higher hydrogen yield than Ni/AZ catalyst. Superior textural properties, high reducibility, and high nickel surface area of Ni–AZ catalyst were responsible for its enhanced catalytic performance in the steam reforming of ethanol.     

Effects of modifying Ni/Al2O3 catalyst with cobalt on the reforming of CH4 with CO2 and cracking of CH4 reactions

Alumina supported nickel (Ni/Al₂O₃), nickel–cobalt (Ni–Co/Al₂O₃) and cobalt (Co/Al₂O₃) catalysts containing 15% metal were synthesized, characterized and tested for the reforming of CH₄ with CO₂ and CH₄ cracking reactions. In the Ni–Co/Al₂O₃ catalysts Ni–Co alloys were detected and the surface metal sites decreased with decrease in Ni:Co ratio. Turnover frequencies of CH₄ were determined for both reactions. The initial turnover frequencies of reforming (TOF_DRM) for Ni–Co/Al₂O₃ were greater than that for Ni/Al₂O₃, which suggested a higher activity of alloy sites. The initial turnover frequencies for cracking (TOF_CRK) did not follow this trend. The highest average TOF_DRM, H₂:CO ratio and TOF_CRK were observed for a catalyst containing a Ni:Co ratio of 3:1. This catalyst also had the maximum carbon deposited during reforming and produced the maximum reactive carbon during cracking. It appeared that carbon was an intermediate product of reforming and the best catalyst was able to most effectively crack CH₄ and oxidize carbon to CO by CO₂.     

Hydrogen and multiwall carbon nanotubes production by catalytic decomposition of methane: Thermogravimetric analysis and scaling-up of Fe–Mo catalysts

Fe-based catalysts doped with Mo were prepared and tested in the catalytic decomposition of methane (CDM), which aims for the co-production of CO₂-free hydrogen and carbon filaments (CFs). Catalysts performance were tested in a thermobalance operating either at isothermal or temperature programmed mode by monitoring the weight changes with time or temperature, respectively, as a result of CF growth on the metal particles. Maximum performance of Fe–Mo catalysts was found at the temperature range of 700–900 °C. The addition of Mo as dopant resulted in an increase in the rate and amount of deposited carbon, reaching an optimum in the range 1.7–5.1% (mol) of Mo for Fe–Mo/Al₂O₃ catalysts, whereas for Fe–Mo/MgO catalyst an optimum at 5.1% Mo loading was obtained. XRD study revealed the effect of the Mo addition on the Fe₂O₃/Fe crystal domain size in the fresh and reduced catalysts. Tubular carbon nanostructures with high structural order were obtained using Fe–Mo catalysts, mainly as multiwall carbon nanotubes (MWCNTs) and bamboo carbon nanotubes. Fe–Mo catalysts showing best results in thermobalance were tested in a rotary bed reactor leading to high conversions of methane (70%) and formation of MWCNTs (5.3 g/h).     

Combination of CO2 reforming and partial oxidation of methane to produce syngas over Ni/SiO2 and Ni–Al2O3/SiO2 catalysts with different precursors

Ni/SiO₂ and Ni–Al₂O₃/SiO₂ catalysts were prepared by incipient wetness impregnation using citrate and nitrate precursors and tested with a reaction of combination of CO₂ reforming and partial oxidation of methane to produce syngas (H₂/CO). The catalytic activity of Ni/SiO₂ and Ni–Al₂O₃/SiO₂ greatly depended on interaction between NiO and support. NiO strongly interacted with support formed small nickel particles (about 4 nm for NiSC which is abbreviation of Ni/SiO₂ prepared with Nickel citrate precursor) after reduction. The small nickel particles over NiSC catalysts exhibited a good catalytic performance.     

Reduction characteristics of CuFe2O4 and Fe3O4 by methane; CuFe2O4 as an oxidant for two-step thermochemical methane reforming

The reduction characteristics of CuFe₂O₄ and Fe₃O₄ by methane at 600–900 °C were determined in a thermogravimetric analyzer for the purpose of using CuFe₂O₄ as an oxidant of two-step thermochemical methane reforming. It was found that the addition of Cu to Fe₃O₄ largely affected the reduction kinetics and carbon formation in methane reduction. In the case of CuFe₂O₄, the reduction kinetics was found to be faster than that of Fe₃O₄. Furthermore, carbon deposition and carbide formation from methane decomposition were effectively inhibited. In case of Fe₃O₄, Fe metal formed from Fe₃O₄ decomposed methane catalytically, that lead to the formation of graphite and Fe₃C phases. It is deduced that Cu in CuFe₂O₄ enhanced reduction kinetics, decreased reduction temperature and prevented carbide and graphite formation. Additionally, methane conversion and CO selectivity in the syngas production step with CuFe₂O₄ were in the range of 33.5–55.6% and 54.9–59.6%, respectively.     

Catalytic conversion of CH4 and CO2 to synthesis gas on Ni/SiO2 catalysts containing Gd2O3 promoter

A series of Ni/SiO₂ catalysts containing different amounts of Gd₂O₃ promoter was prepared, characterized by H₂-adsorption and XRD, and used for carbon dioxide reforming of methane (CRM) and methane autothermal reforming with CO₂ + O₂ (MATR) in a fluidized-bed reactor. The results of pulse surface reactions showed that Ni/SiO₂ catalysts containing Gd₂O₃ promoter could increase the activity for CH₄ decomposition, and Raman analysis confirmed that reactive carbon species mainly formed on the Ni/SiO₂ catalysts containing Gd₂O₃ promoter. In this work, it was found that methane activation and reforming reactions proceeded according to different mechanisms after Gd₂O₃ addition due to the formation of carbonate species. In addition, Ni/SiO₂ catalysts containing Gd₂O₃ promoter demonstrated higher activity and stability in both CRM and MATR reactions in a fluidized bed reactor than Ni/SiO₂ catalysts without Gd₂O₃ even at a higher space velocity.     

Electrocatalysis of carbon black- or chitosan-functionalized activated carbon nanotubes-supported Pd with a small amount of La2O3 towards methanol oxidation in alkaline media

The Pd/C catalysts with and without a small amount of La₂O₃ were synthesized by a simple reduction reaction with sodium borohydride in aqueous solution. The structure and morphology of these catalysts were characterized by X-ray diffraction, energy dispersive X-ray spectroscopy and transmission electron microscopy. The electrocatalytic performance of these catalysts for methanol oxidation in alkaline media was investigated using cyclic voltammetry, chronoamperometry and CO stripping experiments. The results show that the Pd–La₂O₃/C catalyst has a higher catalytic activity than the Pd/C catalyst, but the effect of La₂O₃ cannot be explained by a bi-functional mechanism. X-Ray photoelectron spectroscopy analyses suggest that the higher content of metallic Pd caused by the addition of La₂O₃ contributes to the better catalytic activity of Pd–La₂O₃/C. Based on the good electrocatalytic performance of Pd–La₂O₃/C, the Pd–La₂O₃ catalyst supported on chitosan (CS)-functionalized activated carbon nanotubes was prepared, and it exhibited a better catalytic activity. The improvement is attributed to the good dispersion status of metal particles and the further increase of metallic Pd due to the presence of CS.     

Bio-ethanol,a suitable fuel to produce hydrogen for a molten carbonate fuel cell

Catalytic and technological aspects in the use of bio-ethanol as fuel to produce hydrogen in both internal (IR-MCFC) and indirect internal reforming (IIR-MCFC) configurations have been considered. In MCFC conditions, even operating at total ethanol conversion, hydrogen productivity depends on the catalyst efficiency to convert methane formed through a mechanism, which foresees as first step the dehydrogenation of ethanol to acetaldehyde and as a second step the decomposition of acetaldehyde to CO and CH₄. Potassium doped Ni/MgO, Ni/La₂O₃ and Rh/MgO resulted to be the most promising catalysts to be used for the hydrogen production by steam reforming of bio-ethanol. Coke formation represents a serious problem, however, it can be drastically depressed by adding to the reaction stream a low amount of oxygen.     

Syngas from CO2 reforming of coke oven gas: Synergetic effect of activated carbon/Ni–γAl2O3 catalyst

The CO₂ reforming of coke oven gas for the production of synthesis gas has been studied over an activated carbon, an in-lab prepared Ni/Al₂O₃ catalyst and physical mixtures of both materials in different proportions (AC + Ni) at 800 °C. It was found that there are two possible coexisting reaction pathways: the direct dry reforming of methane (decomposition of methane followed by gasification of the carbon deposits) and the reverse water gas shift reaction followed by the steam reforming of methane. If the process is carried out with the physical mixtures AC + Ni, there is a synergetic effect between both materials. The experimental conversions are higher than the conversions predicted by the law of mixtures, whereas the production of water is lower, resulting in a higher selectivity. The mixtures also showed a lower loss of porosity than when the activated carbon and the in-lab prepared Ni/Al₂O₃ were used individually. Therefore, the combination of these materials may produce catalysts that are more resistant to deactivation. The synthesis gas obtained was analyzed and it was found suitable for the production of methanol.