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.     

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.     

Evaluation of Ni/Y2O3/Al2O3 catalysts for hydrogen production by autothermal reforming of methane

Ni/xY₂O₃–Al₂O₃ (x = 5, 10, 15, 20 wt%) catalysts were prepared by sequential impregnation synthesis. The catalytic performance for the autothermal reforming of methane was evaluated and compared with Ni/γ-Al₂O₃ catalyst. The physicochemical properties of catalysts were characterized by X-ray diffraction (XRD), Transmission electron microscope (TEM), X-Ray Photoelectron Spectrometer (XPS), Thermo Gravimetric Analyzer (TGA) and H₂-temperature programmed reduction techniques (TPR). The decrease of nickel particle size and the change of reducibility were found with Y modification. The CH₄ conversion increased with elevating levels of Y₂O₃ from 5% to 10%, then decreased with Y content from 10% to 20%. Ni/xY₂O₃–Al₂O₃ catalysts maintained high activity after 24 h on stream, while Ni/Al₂O₃ had a significant deactivation. The characterization of spent catalysts indicated that the addition of Y retarded Ni sintering and decreased the amount of coke.     

Comparative study on the promotion effect of Mn and Zr on the stability of Ni/SiO2 catalyst for CO2 reforming of methane

The stability of Mn-promoted Ni/SiO₂ catalyst for methane CO₂ reforming was investigated comparatively to that of Zr-promoted Ni/SiO₂. The catalysts were prepared by the same impregnation method with the same controlled promoter contents and characterized by TPR, XRD, TG, SEM, XPS and Raman techniques. The addition of Mn to Ni/SiO₂ catalyst promoted the dispersion of Ni species, leading to smaller particle size of NiO on the fresh Ni–Mn/SiO₂ catalyst and the formation of NiMn₂O₄, which enhanced the interaction of the modified support with Ni species. Thus, the Ni–Mn/SiO₂ catalyst showed higher activity and better ability of restraining carbon deposition than Ni/SiO₂ catalyst. Besides, it exhibited stable activity at reaction temperatures over the range from 600 °C to 800 °C. However, the introduction of Zr increased the reducibility of Ni–Zr/SiO₂, and the catalyst deactivated much more dramatically when the reaction temperature decreased due to its poor ability of restraining carbon deposition, and its activity decreased monotonically with time on stream at 800 °C.     

Selective CO oxidation on Cu promoted Pt/Al2O3 and Pt/Nb2O5 catalysts

Pt–Cu catalysts supported on Al₂O₃ and Nb₂O₅ were studied for use in selective CO oxidation. The addition of copper enhanced the activity and selectivity of Pt–Cu/Nb₂O₅ at lower temperatures when compared to Pt/Nb₂O₅. On the other hand, copper addition was not beneficial in the case of Al₂O₃ supported catalysts.     

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.     

Nanocrystallites-forming hierarchical porous Ni/Al2O3–TiO2 catalyst for dehydrogenation of organic chemical hydrides

Dehydrogenation of organic chemical hydrides has been improved by reconstructing the catalyst in the form of hierarchical porous structure nanocatalyst, in which the economical Ni was adopted as catalytic component and nano Al₂O₃–TiO₂ hybrid composite as support. The Al₂O₃–TiO₂ composite was prepared by spontaneous self-assembly of nano Al₂O₃ and TiO₂ aggregates by hydrolysis of tetra-n-butyl-titanate under continuous agitation. The multi-scaled distribution of Al₂O₃–TiO₂ aggregates with hierarchy could be observed in dynamic light scattering spectrometer. The aggregates are comprised of nano-sized γ-Al₂O₃ and anatase TiO₂ crystallites with sizes of about 5 and 7 nm, respectively. The surface modulation by TiO₂ could be verified in FTIR Spectra. The migration of Ti species and crystallite growth were hindered by the Al₂O₃ skeleton and the hierarchical porous structure was sustained during the thermal related process. The multi-scaled distributed pores were confirmed by both TEM analysis and N₂ adsorption results. The results of dehydrogenation experiments showed that the hierarchical porous structure nano Ni/Al₂O₃–TiO₂ exhibited superior catalytic performance to Ni/Al₂O₃ with the optimum conversion of 99.9% at 400 °C, while the catalyst of Ni/Al₂O₃ exhibited only 16.5% under the same condition.     

Syngas production via CO2 reforming of methane over plasma assisted synthesized Ni‐Co/Al2O3‐ZrO2 nanocatalysts with different Ni‐loadings

Ni‐Co/Al₂O₃‐ZrO₂ nanocatalysts with 5, 10 and 15 wt.% nominal Ni content have been prepared by impregnation followed by a non‐thermal plasma treatment, characterized and tested for dry reforming of methane. For nanocatalysts characterization the following techniques have been used: XRD, FESEM, TEM, EDX dot‐mapping, BET, FTIR and XPS. The dry reforming of methane was carried out at different temperatures (550‐850 °C) using a feed mixture of CH₄:CO₂ (1:1). Among the nanocatalysts studied, the catalyst with the medium Ni content (10 wt.%) was the most active in dry reforming of methane. This higher activity exhibited by Ni‐Co/Al₂O₃‐ZrO₂ catalyst with medium Ni content (10 wt.% ) can be attributed to small and well dispersed particles of Ni within the catalyst. Apart from the narrow surface particle size distribution in the case of Ni(10 wt.%)‐Co/Al₂O₃‐ZrO₂, the presence of small active components with average size of 7.5 nm is proposed to be the reason for the superior performance of the catalyst. Ni(10 wt.%)‐Co/Al₂O₃‐ZrO₂ nanocatalyst had maximum surface area and the lower surface area was observed in the case of Ni(5 wt.%)‐Co/Al₂O₃‐ZrO₂ and Ni(15 wt.%)‐Co/Al₂O₃‐ZrO₂ due to the formation of the larger agglomeration and higher mean particle size of nickel particles, respectively. Although, GHSV enhancment had inverse effect on product yield but yield reduction for Ni‐Co/Al₂O₃‐ZrO₂ catalyst with 10 wt.% Ni was less drastic at high GHSVs. According to XRD and XPS, existence of NiAl₂O₄ confirms strong interaction between Ni and support but higher loadings of Ni resulted in less NiAl₂O₄; loser interaction between support and active phase. Small particles of active components and well‐defined dispersion of them in Ni(10 wt.%)‐Co/Al₂O₃‐ZrO₂ nanocatalyst resulted in stability of the catalyst for either feed conversion or H₂/CO molar ratio. Copyright © 2013 John Wiley & Sons, Ltd.     

Study on pine biomass air and oxygen/steam gasification in the fixed bed gasifier

The pine biomass gasification under air and oxygen/steam atmosphere was experimentally studied in a fixed bed reactor. The effects of air flow, gasification temperature, oxygen concentration, steam flow and the catalytic cracking reaction temperature on production distribution were investigated. The results indicate that the H₂ content reaches the maximum at the gasification temperature 850 °C for a given air flow. Comparing with air-gasification atmosphere, the lower heating value (LHV) of produced syngas is higher (up to 8.76 MJ/Nm³) under oxygen-enriched gasification atmosphere. And the introduction of steam to the oxygen-enriched gasification leads to a higher H₂ content and LHV of produced synthesis gas. Additionally, the syngas content increases significantly with increasing catalytic cracking reaction temperature when Ni–Al₂O₃ catalyst was employed in catalytic cracking process. The results also reveal that the steam reforming reactions of methane and carbon dioxide are enhanced over Ni–Al₂O₃ catalyst. The effects of different loading of metal oxide additives to Ni–Al₂O₃ catalyst on the catalytic activity were discussed, and it is found that the Fe₂O₃/Ni–Al₂O₃ catalyst shows the best catalytic activity and the H₂ content achieves the maximum value of 39.21 vol.%.     

The surfactant-assisted Ni–Al2O3 catalyst prepared by a homogeneous precipitation method for CH4 steam reforming

The surfactant-assisted Ni–Al₂O₃ catalysts are prepared by the homogeneous precipitation method with a surfactant/Al molar ratio ranging from 0.0 to 2.0. It has been investigated the effects of the surfactant on the physicochemical properties and the catalytic activities of the Ni–Al₂O₃ catalysts. The BET surface area of the catalysts decreases with increasing the surfactant content. The pore volume and pore size of the catalysts increase with increasing the surfactant content. XRD results indicate that all of the catalysts exhibit strong diffraction peaks corresponding to NiO and weak peaks corresponding to NiAl₂O₄. In the TPR results, the reduction peaks which indicates that the Ni particles strongly interacted with the support are present at between 668 and 688 °C. The activities of the prepared catalysts for methane steam reforming increase with increasing surfactant content in fresh and poisoned state due to an increase of pore volume and pore size.     

Steam reforming of methanol over Cu/ZnO/ZrO2/Al2O3 catalyst

Steam reforming of methanol was investigated over Cu–ZnO–ZrO₂–Al₂O₃ catalysts at 473 and 573 K. The Cu:Zn:(Al + Zr) molar ratio was 3:3:4; however, the Zr:Al molar ratio was varied and the catalysts were pretreated at different calcination and reduction temperatures. The synthesized catalysts were characterized by N₂ physisorption, temperature-programmed reduction with H₂ (H₂-TPR), X-ray diffraction, oxidized surface TPR, and infrared spectroscopy after carbon monoxide chemisorption. The crystalline size of Cu decreased on increasing the calcination temperatures from 573 to 623 K and increased on increasing the reduction temperatures from 523 to 573 K. Among the tested catalysts, the Cu–ZnO–ZrO₂ catalyst exhibited the highest and lowest hydrogen-formation rates at 473 and 573 K, respectively. After the reaction at 573 K, all the tested catalysts exhibited an increase in the Cu crystalline size, causing the catalyst deactivation. Among the tested catalysts, the Cu–ZnO–ZrO₂–Al₂O₃ catalyst, where the Cu:Zn:Al:Zr molar ratio was 3:3:2:2, showed the highest and most stable catalytic activity at 573 K. Cu dispersion and catalyst composition affected the catalytic performance for steam reforming of methanol.     

Diesel pre-reforming over highly dispersed nano-sized Ni catalysts supported on MgO–Al2O3 mixed oxides

A highly dispersed 50 wt% Ni/MgO–Al₂O₃ catalyst was prepared by deposition–precipitation (DP) method for the diesel pre-reforming reaction. The pH of the precursor solution was controlled from pH 9.5 to 12.0 to examine the effects on NiO crystallite size and metal dispersion. The increase of pH of the precursor solution causes an increase of specific surface area and metal dispersion, and reduces NiO crystallite size. The pre-reforming reaction was carried out using n-tetradecane as surrogate compound of diesel. The coke formation of used catalysts was examined by TGA, TEM, SEM, and Raman analysis. The 50 wt% Ni/MgO–Al₂O₃ catalyst prepared at pH 11.5 showed a high catalytic activity and excellent coke resistance due to high metal dispersion (8.71%), small NiO crystallite size (3.5 nm), and strong interaction between Ni and support. Furthermore, this catalyst showed a good stability in the pre-reforming reaction at S/C ratio of 3.5 and 450 °C for 88 h.     

Reforming of bioethanol over Ni/Al2O3 and Ni/CeZrO2/Al2O3 catalysts in supercritical water for hydrogen production

Bioethanol was reformed in supercritical water (SCW) at 500 °C and 25 MPa on Ni/Al₂O₃ and Ni/CeZrO₂/Al₂O₃ catalysts to produce high-pressure hydrogen. The results were compared with non-catalytic reactions. Under supercritical water and in a non-catalytic environment, ethanol was reformed to H₂, CO₂ and CH₄ with small amounts of CO and C2 gas and liquid products. The presence of either Ni/Al₂O₃ or Ni/CeZrO₂/Al₂O₃ promoted reactions of ethanol reforming, dehydrogenation and decomposition. Acetaldehyde produced from the decomposition of ethanol was completely decomposed into CH₄ and CO, which underwent a further water-gas shift reaction in SCW. This led to great increases in ethanol conversion and H₂ yield on the catalysts of more than 3-4 times than that of the non-catalytic condition. For the catalytic operation, adding small amounts of oxygen at oxygen to ethanol molar ratio of 0.06 into the feed improved ethanol conversion, at the expense of some H₂ oxidized to water, resulting in a slightly lower H₂ yield. The ceria-zirconia promoted catalyst was more active than the unpromoted catalyst. On the promoted catalyst, complete ethanol conversion was achieved and no coke formation was found. The ceria-zirconia promoter has important roles in improving the decomposition of acetaldehyde, the enhancement of the water-gas shift as well as the methanation reactions to give an extremely low CO yield and a tremendously high H₂/CO ratio. The SCW environment for ethanol reforming caused the transformation of gamma-alumina towards the corundum phase of the alumina support in the Ni/Al₂O₃ catalyst, but this transformation was slowed down by the presence of the ceria-zirconia promoter.     

The effect of preparation method on the catalytic performance over superior MgO-promoted Ni–Ce0.8Zr0.2O2 catalyst for CO2 reforming of CH4

The effect of preparation method on MgO-promoted Ni–Ce_0.8Zr_0.2O₂ catalysts was investigated in CO₂ reforming of CH₄. Co-precipitated Ni–MgO–Ce_0.8Zr_0.2O₂ exhibited very high activity as well as stability (X_CH4 > 95% at 800 °C for 200 h) due to high surface area, high dispersion of Ni, small Ni crystallite size, and easier reducibility. Four elements (Ni, Mg, Ce, and Zr) are located at the same position for the co-precipitated catalyst, resulting in easier reducibility.     

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%.     

Effect of milling methods on performance of Ni–Y2O3-stabilized ZrO2 anode for solid oxide fuel cell

A Ni–YSZ (Y₂O₃-stabilized ZrO₂) composite is commonly used as a solid oxide fuel cell anode. The composite powders are usually synthesized by mixing NiO and YSZ powders. The particle size and distribution of the two phases generally determine the performance of the anode. Two different milling methods are used to prepare the composite anode powders, namely, high-energy milling and ball-milling that reduce the particle size. The particle size and the Ni distribution of the two composite powders are examined. The effects of milling on the performance are evaluated by using both an electrolyte-supported, symmetric Ni–YSZ/YSZ/Ni–YSZ cell and an anode-supported, asymmetric cell. The performance is examined at 800 °C by impedance analysis and current-voltage measurements.     

Effect of Pr addition on the properties of Ni/Al2O3 catalysts with an application in the autothermal reforming of methane

Ni/xPr-Al₂O₃ (x = 5, 10, 15, 20 wt%) catalysts with an application in autothermal reforming of methane were prepared by sequential impregnation synthesis; its catalytic performance was evaluated and compared with that of Ni/γ-Al₂O₃ catalyst; the physicochemical properties of the catalysts were characterized by X-ray diffraction (XRD), Transmission electron microscope (TEM), X-Ray Photoelectron Spectrometer (XPS), Thermo Gravimetric Analyzer (TGA) and H₂-temperature programmed reduction techniques (TPR). The results showed that Pr addition promoted the reduction of nickel particle size on the surface. TPR experiments suggested a heterogeneous distribution of nickel oxide particles over xPr-Al₂O₃ supports and the promotion of NiO reduction by Pr modification. The CH₄ conversion increased with elevating levels of Pr addition from 5% to 10%, then decreased with Pr content from 10% to 20%. For the stability catalytic tests, Ni/xPr-Al₂O₃ catalysts maintained the high activity after 48 h while Ni/Al₂O₃ had a significant deactivation.     

Ni and metal aluminate mixtures for solid oxide fuel cell anode supports

Mixtures of nickel and metal aluminate (Ni–MAl₂O₄ [M = Fe, Co, Ni and Cu]) were fabricated, and their electrical conductivities, microstructures and thermal expansions were measured. During the sintering of these mixtures, MAl₂O₄ reacts with NiO to form NiAl₂O₄ and MO_x which are thought to be the reasons for the differences in the microstructures and electrical properties. Except for FeAl₂O₄, Ni–MAl₂O₄ mixtures show metallic conductivity behavior and their electrical conductivities are sufficient for cell operation. Their thermal expansion coefficients are much lower than conventional Ni-YSZ mixtures and closer to the 8YSZ electrolyte. The peak power densities of single cells supported with Ni–NiAl₂O₄ and Ni–CoAl₂O₄ are 410 and 440 mW cm⁻² at 850 °C, respectively, which are lower than 490 mW cm⁻² of Ni-YSZ. This is due to the polarization resistances of functional anode layer. The Ni–CuAl₂O₄-supported cell has no electrical performance because of Cu migration and segregation.     

Evidence of composition deviation of metal particles of a Ni–Cu/Al2O3 catalyst during methane decomposition to COx-free hydrogen

A coprecipitated Ni–Cu/Al₂O₃ catalyst was examined in a fluidized bed reactor for the decomposition of methane to CO_x-free hydrogen and carbon nanofibers using two different reaction temperature schemes, i.e. constant temperature and pre-induction operation. At constant temperatures, the catalyst showed quasi-stable activity below 913 K for a notable time period, while its performance decayed fast above this temperature and a quick deactivation was observed at 1013 K. However, for reaction at 1013 K, the durability was improved if the catalyst was induced for 10 min at 823 K in the reaction atmosphere. A detailed examination of the metal particles after reaction with EDS revealed that the composition of the metal particle depended strongly on the reaction temperature and the induction scheme. The metal particles in the reduced catalyst showed a composition deviation also. The HRTEM micrographs of the carbon–metal interface and the EDS results support the surface migration and ensemble mechanism for carbon formation and give evidence for the reconstruction of the metal particles during the induction period.     

Effect of Al2O3 content on the adsorptive properties of Cu/ZnO/Al2O3 for removal of odorant sulfur compounds

Cu/ZnO/Al₂O₃ adsorbents for removal of odorant sulfur compounds were prepared with various Al/Cu molar ratios by co-precipitation method. The sulfur removing ability as a function of Al/Cu molar ratio of the adsorbents for t-butyl mercaptan (TBM), tetrahydro thiophene (THT), dimethyl disulfide (DMS) and H₂S were investigated at 250 °C and 6000 h⁻¹ space velocity. Based on the results of adsorption capacity and characterization by various techniques, the optimum Al/Cu ratio for maximum sulfur removal capacity is found to be at Al/Cu molar ratio of 0.15 which possesses the well-dispersed Cu species with high reducibility. The adsorption capacity is highest for H₂S followed by TBM, DMS and THT. The main role of Al₂O₃ component is to provide the dispersion of CuO species homogeneously with small particle formation and high reducibility.