A highly active and stable chromium free iron based catalyst for H2 purification in high temperature water gas shift reaction

In this work mesoporous nanocrystalline chromium free Fe–Al–Ni catalysts with various Fe/Al and Fe/Ni ratios were prepared by coprecipitation method for high temperature water gas shift reaction. The prepared catalysts were characterized using X-ray diffraction (XRD), N₂ adsorption (BET), temperature-programmed reduction (TPR) and transmission electron microscopy (TEM) techniques. The catalytic results revealed that the catalyst with Fe/Al = 10 and Fe/Ni = 5 weight ratios exhibited the highest catalytic activity among the prepared catalysts and the commercial chromium containing one. This catalyst possessed a high surface area of 177.4 m² g⁻¹ with an average pore size of 4.3 nm with a high stability during 20 h time on stream. Furthermore, the effect of calcination temperature, GHSV and steam/gas ratio on the structural properties and catalytic performance of the catalyst with the highest activity was investigated.     

Preparation of nanocrystalline metal (Cr,Al, Mn,Ce, Ni,Co and Cu) modified ferrite catalysts for the high temperature water gas shift reaction

Water gas shift reaction is an essential process of hydrogen production and carbon monoxide removal from syngas. Fe–Cr–Cu catalysts are typical industrial catalysts for high temperature water gas shift reaction but have environmental and safety concerns related to chromium content. In this work nanocrystalline metal (M)-modified ferrite catalysts (M = Cr, Al, Mn, Ce, Ni, Co and Cu) for replacement of chromium were prepared by coprecipitation method and the effects of promoters on the structural and catalytic properties of the iron based catalysts were studied. Prepared catalysts were characterized using X-ray diffraction (XRD), N₂ adsorption (BET), temperature-programmed reduction (TPR) and transmission electron microscopies (TEM) techniques. Temperature-programmed reduction measurements inferred that copper favors the active phase formation and significantly decreased the reduction temperature of hematite to magnetite. In addition, water gas shift activity results revealed that Fe–Al–Cu catalyst with Fe/Al = 10 and Fe/Cu = 5 weight ratios showed the highest catalytic activity among the prepared catalysts. Moreover, the effect of calcination temperature, GHSV and steam/gas ratio on the catalytic performance of this catalyst was investigated.     

Mesoporous CexMn1−xO2 composites as novel alternative carriers of supported Co3O4 catalysts for CO preferential oxidation in H2 stream

The mesoporous Co₃O₄ supported catalysts on Ce–M–O (M = Mn, Zr, Sn, Fe and Ti) composites were prepared by surfactant-assisted co-precipitation with subsequent incipient wetness impregnation (SACP–IWI) method. The catalysts were employed to eliminate trace CO from H₂-rich gases through CO preferential oxidation (CO PROX) reaction. Effects of M type in Ce–M–O support, atomic ratio of Ce/(Ce + Mn), Co₃O₄ loading and the presence of H₂O and CO₂ in feed were investigated. Among the studied Ce–M–O composites, the Ce–Mn–O is a superior carrier to the others for supported Co₃O₄ catalysts in CO PROX reaction. Co₃O₄/Ce_0.9Mn_0.1O₂ with 25 wt.% loading exhibits excellent catalytic properties and the 100% CO conversion can be achieved at 125–200 °C. Even with 10 vol.% H₂O and 10 vol.% CO₂ in feed, the complete CO transformation can still be maintained at a wide temperature range of 190–225 °C. Characterization techniques containing N₂ adsorption/desorption, X-ray diffraction (XRD), H₂ temperature-programmed reduction (H₂-TPR) and scanning electron microscopy (SEM) were employed to reveal the relationship between the nature and catalytic performance of the developed catalysts. Results show that the specific surface area doesn’t obviously affect the catalytic performance of the supported cobalt catalysts, but the right M type in carrier with appropriate amount effectively improves the Co₃O₄ dispersibility and the redox behavior of the catalysts. The large reducible Co³⁺ amount and the high tolerance to reduction atmosphere resulted from the interfacial interaction between Co₃O₄ and Ce–Mn support may significantly contribute to the high catalytic performance for CO PROX reaction, even in the simulated syngas.     

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.     

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.     

Spectroscopic characterization of Mn–Co–Ce mixed oxides,active catalysts for COPROX reaction

Mn–Co–Ce mixed oxides are active and selective catalysts for the CO preferential oxidation (COPROX), which is a promising process for the purification of hydrogen streams. In this work, we report a careful spectroscopic characterization of the said system, with the aim of relating its physical chemistry properties to the catalytic behavior. In all the Co–Mn–Ce samples, we detected the formation of partially developed (Mn,Co)₃O₄ mixed spinels. The presence of these species, which can be reduced during the TPR experiments at an intermediate temperature range (300–600 °C), was also suggested by XRD and LRS. XPS results show that in all cases the catalytic surface is enriched in Mn, while the opposite occurs for Co. As regards the catalytic activity, we observed that the best formulations were those containing intermediate Mn/Co ratios (1/4 and 1/1), which can be ascribed to the promoting effect of Mn in improving the redox properties of Co active sites and provoking an increase in surface area. The best catalyst, which has a Mn/Co ratio of 1/4, was very stable after 75 h of time-on-stream with CO₂ included in the feed.     

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.     

Y2O3-promoted NiO/SBA-15 catalysts highly active for CO2/CH4 reforming

A series of Y₂O₃-promoted NiO/SBA-15 (9 wt% Ni) catalysts (Ni:Y weight ratio = 9:0, 3:1, 3:2, 1:1) were prepared using a sol–gel method. The fresh as well as the catalysts used in CO₂ reforming of methane were characterized using N₂-physisorption, XRD, FT-IR, XPS, UV, HRTEM, H₂-TPR, O₂-TPD and TG techniques. The results indicate that upon Y₂O₃ promotion, the Ni nanoparticles are highly dispersed on the mesoporous walls of SBA-15 via strong interaction between metal ions and the HO–Si-groups of SBA-15. The catalytic performance of the catalysts were evaluated at 700 °C during CH₄/CO₂ reforming at a gas hourly space velocity of 24 L g_cat⁻¹ h⁻¹(at 25 ^°C and 1 atm) and CH₄/CO₂molar ratio of 1. The presence of Y₂O₃ in NiO/SBA-15 results in enhancement of initial catalytic activity. It was observed that the 9 wt% Y–NiO/SBA-15 catalyst performs the best, exhibiting excellent catalytic activity, superior stability and low carbon deposition in a time on stream of 50 h.     

Hydrogen production from catalytic steam reforming of bio-oil aqueous fraction over Ni/CeO2–ZrO2 catalysts

A series of composite catalysts Ni/CeO₂–ZrO₂ were prepared via impregnation method with Ni as the active metal. A laboratory-scale fixed-bed reactor was employed to investigate the catalyst performance during hydrogen production by steam reforming bio-oil aqueous fraction. Effects of water-to-bio-oil ratio (W/B), reaction temperature, and the loaded weight of Ni and Ce on the hydrogen production performance of Ni/CeO₂–ZrO₂ catalysts were examined. The obtained results were compared with commercial nickel-based catalysts (Z417). The best performance of Ni/CeO₂–ZrO₂ catalyst was observed when the Ni and Ce loaded weight were 12% and 7.5% respectively. At W/B = 4.9, T = 800 °C, H₂ yield reaches the highest of 69.7% and H₂ content of 61.8% were obtained. Under the same condition, H₂ yield and H₂ content were higher than commercial nickel-based catalysts (Z417).     

Hydrogen production by auto-thermal reforming of ethanol over nickel catalyst supported on metal oxide-stabilized zirconia

Metal oxide-stabilized mesoporous zirconia supports (M–ZrO₂) with different metal oxide stabilizer (M = Zr, Y, La, Ca, and Mg) were prepared by a templating sol–gel method. 20 wt% Ni catalysts supported on M–ZrO₂ (M = Zr, Y, La, Ca, and Mg) were then prepared by an incipient wetness impregnation method for use in hydrogen production by auto-thermal reforming of ethanol. The effect of metal oxide stabilizer (M = Zr, Y, La, Ca, and Mg) on the catalytic performance of supported nickel catalysts was investigated. Ni/M–ZrO₂ (M = Y, La, Ca, and Mg) catalysts exhibited a higher catalytic performance than Ni/Zr–ZrO₂, because surface oxygen vacancy of M–ZrO₂ (M = Y, La, Ca, and Mg) and reducibility of Ni/M–ZrO₂ (M = Y, La, Ca, and Mg) were enhanced by the addition of lower valent metal cation. Hydrogen yield over Ni/M–ZrO₂ (M = Zr, Y, La, Ca, and Mg) catalyst was monotonically increased with increasing both surface oxygen vacancy of M–ZrO₂ support and reducibility of Ni/M–ZrO₂ catalyst. Among the catalysts tested, Ni catalyst supported on yttria-stabilized mesoporous zirconia (Ni/Y–ZrO₂) showed the best catalytic performance.     

Syngas production by CO2 reforming of coke oven gas over Ni/La2O3–ZrO2 catalysts

Syngas production by CO₂ reforming of coke oven gas (COG) was studied in a fixed-bed reactor over Ni/La₂O₃–ZrO₂ catalysts. The catalysts were prepared by sol–gel technique and tested by XRF, BET, XRD, H₂-TPR, TEM and TG–DSC. The influence of nickel loadings and calcination temperature of the catalysts on reforming reaction was measured. The characterization results revealed that all of the catalysts present excellent resistance to coking. The catalyst with appropriate nickel content and calcination temperature has better dispersion of active metal and higher conversion. It is found that the Ni/La₂O₃–ZrO₂ catalyst with 10 wt% nickel loading provides the best catalytic activity with the conversions of CH₄ and CO₂ both more than 95% at 800 °C under the atmospheric pressure. The Ni/La₂O₃–ZrO₂ catalysts show excellent catalytic performance and anti-carbon property, which will be of great prospects for catalytic CO₂ reforming of COG in the future.     

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.     

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.     

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).     

Hydrogen production through the aqueous phase reforming of ethylene glycol over supported Pt-based bimetallic catalysts

The catalytic activities of supported Pt-based bimetallic catalysts (Pt-M) were studied for hydrogen production via aqueous phase reforming (APR) using a 10 wt% ethylene glycol solution. The catalysts and supports used were characterized via X-ray powder diffraction (XRD), transmission electron microscopy (TEM), nitrogen adsorption-desorption, CO chemisorption, and temperature programmed reduction (TPR) techniques. It was found that the Pt–Mn (Pt:Mn = 1:1, molar ratio) bimetallic catalyst significantly enhanced the catalytic performances such as the hydrogen yield and hydrogen production when compared with monometallic catalysts and other bimetallic catalysts that were examined. The XRD and TPR studies confirmed the interaction between the Pt and Mn species, leading to the Pt–Mn alloys supported on CMK-3. Related to the effect of the type of support, the CMK-3 support demonstrated better performance than the commercial activated carbon and alumina. Accordingly, it can be understood that the better catalytic performance of the APR reaction over Pt–Mn/CMK-3 catalyst is dependent on the alloy effect as well as the structural properties and nature of support given by the addition of the second metal.     

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.     

H2 and CO production over a stable Ni–MgO–Ce0.8Zr0.2O2 catalyst from CO2 reforming of CH4

Ni–Ce_0.8Zr_0.2O₂ and Ni–MgO–Ce_0.8Zr_0.2O₂ catalysts were investigated for H₂ production from CO₂ reforming of CH₄ reaction at a very high gas hourly space velocity of 480,000 h⁻¹. Ni–MgO–Ce_0.8Zr_0.2O₂ exhibited higher catalytic activity and stability (CH₄ conversion >95% at 800 °C for 200 h). The outstanding catalytic performance is mainly due to the basic nature of MgO and an intimate interaction between Ni and MgO.     

Ethanol steam reforming over Ni–Fe-based hydrotalcites: Effect of iron content and reaction temperature

Ethanol steam reforming has been evaluated over nickel–iron based hydrotalcite-like compounds with Ni/Fe molar ratios of 1 and 0.5. Calcined materials have been characterized by XRD, TEM, BET and TPR. The introduction of iron leads to the formation of a mixture of Ni(Fe)O_x and spinel phase upon calcination, which results in variations of structural and catalytic properties. With a Ni/Fe ratio of 1, a remarkable improvement in catalytic activity as well as selectivity to hydrogen is observed with respect to the catalyst with Ni/Fe ratio of 0.5. This is due to the enhanced nickel dispersion, the high surface area, and small Ni⁰ crystallite size over the Ni(Fe)O_x + NiFe₂O₄ mixture. However, a further increase in iron content leads to the formation of a low surface area spinel phase (NiFe₂O₄), which results in lower activity and faster deactivation in the reaction through Ni⁰ sintering. The effect of reaction temperature has been evaluated over the most active catalyst (Ni/Fe = 1).     

Bismuth effect on the Co–Mn/Ce0.85Zr0.15O2 nanoparticulate for CO preferential oxidation in simulated syngas

The novel and efficient bismuth modified supported Co–Mn catalysts were prepared and employed to catalyze the preferential oxidation of CO (CO PROX) in simulated syngas. The effects of introducing-methods and loadings of bismuth on both catalytic performance and catalyst nature were investigated. The N₂ adsorption/desorption measurement, X-ray diffraction (XRD) and H₂-temperature programmed reduction (H₂-TPR), and O₂-TPD (O₂-temperature programmed desorption) characterization techniques were performed to reveal the relationship between the catalytic properties and the nature of the catalysts. Results demonstrate that the as-prepared Bi modified supported Co–Mn catalyst exhibits excellent catalytic performance, depending on the introducing method and loadings of Bi. The enhancement of Bi addition into supported Co–Mn catalyst in the catalytic performance for CO PROX reaction is mainly ascribed to the dramatically improved reducibility of the Bi modified sample. Moreover, the decrease in hydrogen transformation over the Bi modified samples can be observed, suggesting the introduction of Bi can compress the catalytic activity for hydrogen oxidation. This study definitely demonstrates the existence of synergistic effect between the added bismuth and Co–Mn/Ce_0.85Zr_0.15O₂ in the Bi modified supported Co–Mn catalyst for CO PROX reaction. The developed Co₃O₄–MnO_x/Ce_0.85Zr_0.15O₂–Bi₂O₃ catalyst with bismuth content of 4.2 wt.% presents the outstanding catalytic activity, selectivity, and durability for CO PROX reaction in the simulated syngas, and it can be considered as a promising candidate for highly efficient CO elimination from H₂-rich stream.     

CeO2–ZrO2-promoted CuO/ZnO catalyst for methanol steam reforming

The Cu-based catalysts with different supports (CeO₂, ZrO₂ and CeO₂–ZrO₂) for methanol steam reforming (MSR) were prepared by a co-precipitation procedure, and the effect of different supports was investigated. The catalysts were characterized by means of N₂ adsorption–desorption, X-ray diffraction, temperature-programmed reduction, oxygen storage capacity and N₂O titration. The results showed that the Cu dispersion, reducibility of catalysts and oxygen storage capacity evidently influenced the catalytic activity and CO selectivity. The introduction of ZrO₂ into the catalyst improved the Cu dispersion and catalyst reducibility, while the addition of CeO₂ mainly increased oxygen storage capacity. It was noticed that the CeO₂–ZrO₂-containing catalyst showed the best performance with lower CO concentration, which was due to the high Cu dispersion and well oxygen storage capacity. Further investigation illuminated that the formation of CO on CuO/ZnO/CeO₂–ZrO₂ catalyst mainly due to the reverse water gas shift. In addition, the CuO/ZnO/CeO₂–ZrO₂ catalyst also had excellent reforming performance with no deactivation during 360 h run time and was used successfully in a mini reformer. The maximum hydrogen production rate in the mini reformer reached to 162.8 dm³/h, which can produce 160–270 W electric energy power by different kinds of fuel cells.