Activity and stability of alumina zeolite nickel catalysts

The catalytic properties of nickel catalysts (50 wt.% of alumina and 50 wt.% of Ni,H-ZSM-5) were investigated and related to the amount of NiO (0–8 wt.%) and the method of nickel incorporation (8 wt.% NiO). Consideration was also given to the method by which zeolite and alumina were combined. The cracking properties of the catalysts increased when the amount of NiO was raised up to 4 wt.%. To decrease the content of aromatic hydrocarbons in the products it is necessary to raise the amount of NiO to a higher level than 4 wt.%. The catalyst prepared by peptisation of the mixture of zeolite and aluminium hydrogel (with ageing process) displayed reduced activity and stability because of the low susceptibility of NiO to reduction.     

The influence of zeolite acidity for the coupled hydrogenation and ring opening of 1-methylnaphthalene on Pt/USY catalysts

The influence of framework and extraframework composition of USY zeolite on the catalytic performance of bifunctional Pt/USY (1 wt.% Pt) catalysts for the coupled hydrogenation and ring opening of 1-methylnaphthalene (1-MN) has been studied on a continuous fixed bed high pressure reactor. All Pt/USY catalysts showed very high methylnaphthalene (MN) conversions under the reaction conditions studied (T=300–375 °C, P=4.0 MPa, WHSV=2 h⁻¹, H₂/1-MN=30 mol/mol). Product yields and selectivities were mainly determined by the zeolite composition (i.e. acidity). Selectivity to products with the same number of carbon atoms than the feed (C11) increased, at constant temperature, with decreasing the Brönsted acidity of the USY zeolite, that is, with decreasing the concentration of framework Al (FAL) and increasing extraframework Al (EFAL). Selectivity to high cetane ring opening products (ROP=C11-alkylbenzenes (C11AB) and C11-alkylcycloalkanes) within the C11 fraction was higher for the less acidic catalysts. A maximum yield of ROP of ca. 15 wt.% at a C11 yield of ca. 73 wt.% was obtained at 350 °C (P=4.0 MPa, WHSV=2 h⁻¹, H₂/1-MN=30 mol/mol) for a USY zeolite with an intermediate degree of dealumination (a₀=24.33 Å) and containing all the EFAL (bulk Si/Al ratio of 2.6). For this catalyst, a slight increase in ROP yield (ca. 17 wt.%) at similar C11 yield (ca. 74 wt.%) was obtained by working at lower temperature (300 °C) and lower space velocity. Increasing the reaction pressure above 4.0 MPa had only a marginal influence on product yields and selectivities.     

Production of hydrogen for fuel cells by steam reforming of ethanol over supported noble metal catalysts

The catalytic performance of supported noble metal catalysts for the steam reforming (SR) of ethanol has been investigated in the temperature range of 600–850 °C with respect to the nature of the active metallic phase (Rh, Ru, Pt, Pd), the nature of the support (Al₂O₃, MgO, TiO₂) and the metal loading (0–5 wt.%). It is found that for low-loaded catalysts, Rh is significantly more active and selective toward hydrogen formation compared to Ru, Pt and Pd, which show a similar behavior. The catalytic performance of Rh and, particularly, Ru is significantly improved with increasing metal loading, leading to higher ethanol conversions and hydrogen selectivities at given reaction temperatures. The catalytic activity and selectivity of high-loaded Ru catalysts is comparable to that of Rh and, therefore, ruthenium was further investigated as a less costly alternative. It was found that, under certain reaction conditions, the 5% Ru/Al₂O₃ catalyst is able to completely convert ethanol with selectivities toward hydrogen above 95%, the only byproduct being methane. Long-term tests conducted under severe conditions showed that the catalyst is acceptably stable and could be a good candidate for the production of hydrogen by steam reforming of ethanol for fuel cell applications.     

Effects of small MoO3 additions on the properties of nickel catalysts for the steam reforming of hydrocarbons: II. Ni---Mo/Al2O3 catalysts in reforming, hydrogenolysis and cracking of n-butane

Addition of molybdenum to nickel catalysts has a favourable effect on their properties in the steam reforming of hydrocarbons. Some attempts were made to explain the mechanism of promoter action by determining the properties of such catalysts in hydrogenolysis and cracking reactions. With small amounts of promoter (≤0.5 wt.%) advantageneous changes in selectivity of steam reforming and disadvantageneous changes in n-butane hydrogenolysis were observed. The promoter does not affect practically the catalyst properties in n-butane cracking. The effect of molybdenum was compared with that of potassium promoter applied in the industry.     

Catalyst design and development for upgrading aromatic hydrocarbons

Background and strategy of catalyst development for upgrading aromatic hydrocarbons are intensively discussed. Originally prepared catalysts (hydrogenation and hydrocracking catalysts) were used for accelerated aging tests. Though each catalyst showed superior catalytic performance as compared to commercially available catalysts, a severe deactivation was observed on the hydrocracking (HC) catalysts. A new type of HC catalyst was designed and prepared, based on the understanding of catalyst deactivation. High silica NaY zeolites were synthesized using crown-ether. USY zeolites were then prepared by ion exchange, steaming and calcining. Surface properties and catalytic functions of well-crystallized USY zeolites were investigated to develop practical HC catalysts. The Ni–W catalyst prepared using the newly prepared USY zeolite showed a considerable improvement in the HC activity.     

Development of Fe Fischer–Tropsch catalysts for slurry bubble column reactors

The effect of two binder systems — a silica-based system and a silica–kaolin–clay–phosphate-based system — on a doubly promoted Fischer–Tropsch (FT) synthesis iron catalyst (100Fe/5Cu/4.2K) was studied. The catalysts were prepared by coprecipitation, followed by binder addition and spray drying at 270°C in a 1 m diameter, 2 m tall spray dryer. The binder silica content was varied from 0 to 20 wt.%. A catalyst with 12 wt.% binder silica was found to have the highest attrition resistance. The FT activity and selectivity of this catalyst are better than a Ruhrchemie catalyst at 270°C and 1.48 MPa. The addition of precipitated silica or kaolin to catalysts containing 10–12 wt.% binder silica decreases attrition resistance and increases methane selectivity. Based on the experience gained, a catalyst has been successfully spray dried in 500 g quantity. This catalyst showed 95% CO conversion over 125 h of testing at 270°C, 1.48 MPa, and 2 NL/g-cat/h and had less than 4% methane selectivity. Its attrition resistance was one of the highest among the catalysts tested.     

Total oxidation catalysts based on manganese or copper oxides and platinum or palladium II: Activity, hydrothermal stability and sulphur resistance

Deactivation of catalysts based on either manganese oxides, copper oxides, platinum, palladium or combinations of these metal oxides and noble metals supported on γ-alumina was studied. The activity of the catalysts for the oxidation of carbon monoxide, naphthalene and methane, in a mixture resembling the flue gases from wood combustion, was measured before and after exposure of the catalysts either to a temperature of 900°C in the presence of steam or to sulphur dioxide. Most of the mixed catalysts were more resistant to hydrothermal and sulphur treatments than the catalysts with a single active component. After the hydrothermal treatment the activity of the MnO_x catalyst was enhanced. When Pt is combined with MnO_x or CuO_x, the loss of activity of Pt was decreased during the hydrothermal treatment. Also, the hydrotreated mixed MnO_x–Pd and CuO_x–Pd catalysts were more active than the treated Pd catalyst for the oxidation of methane. After sulphur treatment, the activities of the mixed MnO_x–Pt (Pt: 0.05 mol%), MnO_x–Pd and CuO_x–Pd catalysts were improved for the oxidation of carbon monoxide and naphthalene. Among the catalysts studied, the MnO_x–Pt, CuO_x–Pt and CuO_x–Pd catalysts, with a metal oxide and a noble metal loading of 10 and 0.1 mol%/γ-alumina, respectively, had the best combination of activity, thermal stability and resistance to sulphur treatment.     

Investigation of the catalytic performance of Ni/MgO catalysts in partial oxidation,dry reforming and combined reforming of methane

Dry reforming, partial oxidation and combined reforming of methane (combination of partial oxidation and dry reforming) to synthesis gas over nickel catalysts supported on nanocrystalline magnesium oxide with various nickel loadings have been studied. Among the catalysts evaluated, catalyst with 15 wt.% nickel content revealed the most active catalytic performance toward dry reforming, partial oxidation and combined reforming reactions. In addition, catalyst with 5 wt.% nickel loading was employed in long term stability test and has shown stable catalytic performance up to 50 h time on stream without any decrease in methane conversion in these three processes.     

Characterization and activity of copper and nickel catalysts for the oxidation of phenol aqueous solutions

Catalysts based on CuO/γ-alumina, CuAl₂O₄/γ-alumina, NiO/γ-alumina, NiAl₂O₄/γ-alumina and bulk CuAl₂O₄ have been structurally characterized by BET, porosimetry, X-ray diffraction (XRD) and scanning electron microscopy (SEM). Their catalytic behaviors have also been tested for the oxidation of 5 g/l phenol aqueous solutions using a triphasic tubular reactor working in a trickle-bed regime and air with an oxygen partial pressure of 0.9 MPa at a temperature of 413 K. The copper and nickel catalysts supported on γ-alumina have surface areas of the same order as the support γ-alumina of ca. 190 m²/g and high active phase dispersions which were also confirmed by SEM, whereas the bulk copper aluminate spinel has a surface area of ca. 30 m²/g. XRD detects the phases present and shows a continuous loss of CuO by elution and the formation of a copper oxalate phase on the surface of the copper catalysts which also elutes with time. The NiO was also eluted but less than the copper catalysts. Only the copper and nickel spinel catalysts were stable throughout the reaction. Phenol conversion vs. time shows a continuous overall decrease in activity for the CuO/γ-alumina and NiO/γ-alumina catalysts. In turn, the copper and nickel spinel catalysts reach steady activity plateaus of 40 and 10%, respectively, of phenol conversion. The bulk copper aluminate spinel shows an activity plateau of 20% of the conversion which is lower than that from the copper aluminate/γ-alumina catalyst due to its lower surface area. Nickel catalysts always have lower activities than the copper catalysts for the phenol oxidation reaction. The copper catalysts drive a mechanism of partial phenol oxidation to carboxylic acids and quinone-related products with very high specific rates, and the nickel catalysts mainly drive a mechanism of CO₂ formation with lower conversion but with a potential higher catalyst life. The triphasic tubular reactor using trickle-bed regime largely avoids the mechanism of polymer formation as a catalyst deactivation process.     

Steam reforming of ethanol over skeletal Ni‐based catalysts: A temperature programmed desorption and kinetic study

An investigation on reaction scheme and kinetics for ethanol steam reforming on skeletal nickel catalysts is described. Catalytic activity of skeletal nickel catalyst for low‐temperature steam reforming has been studied in detail, and the reasons for its high reactivity for H₂ production are attained by probe reactions. Higher activity of water gas shift reaction and methanation contributes to the low CO selectivity. Cu and Pt addition can promote WGSR and suppress methanation, and, thus, improve H₂ production. A reaction scheme on skeletal nickel catalyst has been proposed through temperature programmed reaction spectroscopy experiments. An Eley‐Rideal model is put forward for kinetic studies, which contains three surface reactions: ethanol decomposition, water gas shift reaction, and methane steam reforming reaction. The kinetics was studied at 300–400°C using a randomized algorithms method and a least‐squares method to solve the differential equations and fit the experimental data; the goodness of fit obtained with this model is above 0.95. The activation energies for the ethanol decomposition, methane steam reforming, and water gas shift reaction are 187.7 kJ/mol, 138.5 kJ/mol and 52.8 kJ/mol, respectively. Thus, ethanol decomposition was determined to be the rate determining reaction of ethanol steam reforming on skeletal nickel catalysts. © 2013 American Institute of Chemical Engineers AIChE J 60: 635–644, 2014     

Ni Catalysts Supported on Mesoporous Nanocrystalline Magnesium Silicate in Dry and Steam Reforming Reactions

Mesoporous nanocrystalline MgSiO₃ with high surface area was synthesized by a hydrothermal method and employed as support in dry and steam reforming of methane. Ni/MgSiO₃ catalysts were prepared by an impregnation method and characterized by different techniques. N₂ adsorption analysis indicated that addition of nickel shifted the pore size distributions to smaller sizes. Temperature‐programmed reduction analysis revealed that a higher nickel loading enhanced the reducibility of the catalyst. The catalytic performance was improved with increasing the nickel content. The Ni/MgSiO₃ catalyst exhibited high stability in dry reforming but methane conversion declined with time‐on‐stream in the steam reforming reaction. Temperature‐programmed oxidation profiles of spent catalysts indicated that the high amount of carbon deposited on the catalyst surface in dry and steam reforming was assigned to whisker‐type carbon.     

Coprecipitated iron-containing catalysts (Fe-Al2O3, Fe-Co-Al2O3, Fe-Ni-Al2O3) for methane decomposition at moderate temperatures: Part II. Evolution of the catalysts in reaction

Coprecipitated Fe-Al₂O₃, Fe-Co-Al₂O₃ and Fe-Ni-Al₂O₃ catalysts is shown to be very efficient in carbon deposition during methane decomposition at moderate temperatures (600–650 °C). The carbon capacity of the most efficient bimetallic catalysts containing 50–65 wt.% Fe, 5–10 wt.% Co (or Ni) and 25–40 wt.% Al₂O₃ is found to reach 145 g/g_cat. Most likely, their high efficiency is due to specific crystal structures of the metal particles and formation of optimum particle size distribution. According to the TEM data, catalytic filamentous carbon (CFC) is formed on them as multiwall carbon nanotubes (MWNTs). The phase composition of the catalysts during methane decomposition is studied using a complex of physicochemical methods (XRD, REDD, Mössbauer spectroscopy and EXAFS). Possible mechanisms of the catalyst deactivation are discussed.     

A dual catalyst bed for the autothermal partial oxidation of methane to synthesis gas

Dual bed catalysts were found to produce high yields (>85%) of hydrogen from methane and air in a millisecond contact time reactor. The dual bed catalyst consisted of a 5 mm platinum combustion catalyst followed by a 5 mm nickel steam reforming catalyst. The platinum catalyst was used to totally oxidize approximately one-quarter of the methane feed to carbon dioxide and water. In the nickel catalyst, the carbon dioxide and water reformed the remaining methane to hydrogen and carbon monoxide. This process is favored at high flow rates, because the heat generated in the platinum catalyst is convected to the nickel catalyst at a higher rate. The heat delivered to the nickel catalyst favors the endothermic reforming reactions that generate the hydrogen and carbon monoxide.     

Characterization and activity in dry reforming of methane on NiMg/Al and Ni/MgO catalysts

Dry reforming of methane has been investigated on two series of catalysts either prepared by co-precipitation: n(Ni_xMg_y)/Al, Ni_xMg_y and Ni_xAl_y or prepared by impregnation: Ni/MgO (mol% Ni = 5, 10). The catalysts, calcined at 600–900 °C, were characterized by different techniques: BET, H₂-TPR, TPO, XRD, IR, and TEM-EDX analysis. The surface BET (30–182 m² g⁻¹) decreased with increasing the temperature of calcination, after reduction and in the presence of Mg element. The XRD analysis showed, for n(Ni_xMg_y)/Al catalysts, the presence of NiAl₂O₄ and NiO–MgO solid solutions. The catalyst reducibility decreased with increasing the temperature of pretreatment. The n(Ni_xMg_y)/Al catalysts were active for dry reforming of methane with a good resistance to coke formation. The bimetallic catalyst Ni_0.05Mg_0.95 (calcined at 750 °C and tested at 800 °C) presents a poor activity. In contrast, the 5% Ni/MgO catalyst, having the same composition but prepared by impregnation, presents a high activity for the same calcination and reaction conditions. For all the catalysts the activity decreased with increasing the temperature of calcination and a previous H₂-reduction of the catalyst improves the performances. The TPO profiles and TEM-EDX analysis showed mainly four types of coke: CH_x species, surface carbon, nickel carbide and carbon nanotubes.     

Tri-reforming of methane: a novel concept for catalytic production of industrially useful synthesis gas with desired H2/CO ratios

A novel process concept called tri-reforming of methane has been proposed in our laboratory using CO₂ in the flue gases from fossil fuel-based power plants without CO₂ separation [C. Song, Chemical Innovation 31 (2001) 21–26]. The proposed tri-reforming process is a synergetic combination of CO₂ reforming, steam reforming, and partial oxidation of methane in a single reactor for effective production of industrially useful synthesis gas (syngas). Both experimental testing and computational analysis show that tri-reforming can not only produce synthesis gas (CO + H₂) with desired H₂/CO ratios (1.5–2.0), but also could eliminate carbon formation which is usually a serious problem in the CO₂ reforming of methane. These two advantages have been demonstrated by tri-reforming of CH₄ in a fixed-bed flow reactor at 850 °C with supported nickel catalysts. Over 95% CH₄ conversion and about 80% CO₂ conversion can be achieved in tri-reforming over Ni catalysts supported on an oxide substrate. The type and nature of catalysts have a significant impact on CO₂ conversion in the presence of H₂O and O₂ in tri-reforming in the temperature range of 700–850 °C. Among all the catalysts tested for tri-reforming, their ability to enhance the conversion of CO₂ follows the order of Ni/MgO > Ni/MgO/CeZrO > Ni/CeO₂ ≈ Ni/ZrO₂ ≈ Ni/Al₂O₃ > Ni/CeZrO. The higher CO₂ conversion over Ni/MgO and Ni/MgO/CeZrO in tri-reforming may be related to the interaction of CO₂ with MgO and more interface between Ni and MgO resulting from the formation of NiO/MgO solid solution. Results of catalytic performance tests over Ni/MgO/CeZrO catalysts at 850 °C and 1 atm with different feed compositions confirm the predicted equilibrium conversions based on the thermodynamic analysis for tri-reforming of methane. Kinetics of tri-reforming were also examined. The reaction orders with respect to partial pressures of CO₂ and H₂O are different over Ni/MgO, Ni/MgO/CeZrO, and Ni/Al₂O₃ catalysts for tri-reforming.     

An examination of the role of plasma treatment for lean NOx reduction over sodium zeolite Y and gamma alumina Part 1. Plasma assisted NOx reduction over NaY and Al2O3

The role of plasma processing on NO_x reduction over γ-alumina and a basic zeolite, NaY was examined. During the plasma treatment NO is oxidized to NO₂ and propylene is partially oxidized to CO, CO₂, acetaldehyde, and formaldehyde. With plasma treatment, NO as the NO_x gas, and a NaY catalyst, the maximum NO_x conversion was 70% between 180 and 230 °C. The activity decreased at higher and lower temperatures.

As high as 80% NO_x removal over gamma alumina was measured by a chemiluminescent NO_x meter with plasma treatment and NO as the NO_x gas.

For both catalysts a simultaneous decrease in NO_x and aldehydes concentrations was observed, which suggests that aldehyde may be important components for NO_x reduction in plasma-treated exhaust.     

Thermal stability of metal-supported catalysts for reduction of cold-start emissions in a wood-fired domestic boiler

The aim of the present work is to develop a catalyst based on a mixture of manganese oxides and platinum supported on a metallic monolith for abatement of emissions from wood combustion, particularly during the cold-start phase. The activity and the thermal stability of the catalysts have been studied in the laboratory, before performing tests in a wood-stove. The effect of the hydrothermal treatment at 900°C on the adherence of the washcoat onto a metallic substrate was studied using scanning electronic microscope. It revealed well-adhering washcoat onto the metallic support due to the growth of the alumina whiskers during the treatment. The influence of the amount of washcoat, as well as the influence of the concentration of manganese oxides in it (Mn: 5 to 20 mol%/Al₂O₃) on the activity of fresh and hydrothermally-treated catalysts were studied. The activity tests were carried out using a mixture of carbon monoxide, naphthalene and methane in the presence of air, steam and carbon dioxide to resemble the flue gases from wood combustion. On the fresh catalysts, containing the same total amount of manganese, a high concentration of manganese oxides in the washcoat favoured the oxidation of carbon monoxide and naphthalene, whereas a lower concentration of manganese oxides in the washcoat gave higher activity for the oxidation of methane. An increased total amount of manganese oxides in the catalysts, which had the same amount of washcoat, resulted in an increase in activity for the oxidation of the three combustibles. After thermal treatment at 900°C for 270 h in steam, most of the manganese oxide catalysts were activated for the oxidation of carbon monoxide and naphthalene while only being slightly deactivated for the oxidation of methane. The addition of manganese oxides in the washcoat, however, lowers the temperature of the γ- to -alumina phase transformation. Platinum (0.5 mol%) was added to the manganese oxide (10 mol%) catalyst to improve its activity. A platinum catalyst was also tested for comparison. The platinum and the mixed catalysts showed similar activity for the oxidation of carbon monoxide and naphthalene, while the mixed catalysts were more active for the oxidation of methane. A similarly mixed MnO_x–Pt (10–0.5 mol%) catalyst supported on Al₂O₃ stabilised with 3% lanthanum, but at larger scale, was tested in a wood-stove. The possibility of pre-heating the catalyst during the start-up phase was studied. The tests revealed a strong decrease of the carbon monoxide and unburned hydrocarbons emissions during the start-up phase when the catalyst was pre-heated with hot air compared with no pre-heating or no catalyst.     

Supported nickel catalysts with a controlled molecular architecture for the catalytic reformation of methane

In this work a lanthanum and nickel catalyst having perovskite structure, grown on a γ-alumina carrier, is being presented. The structure of the catalyst was confirmed by XRD. The behaviour of this material under the conditions of steam reforming has been studied and the influence of the temperature, the space velocity and the steam/carbon ratio on the conversion of methane and the product distribution in the process was determined. In all cases at higher temperatures conversions of more than 90% and high selectivities were achieved. The experiments to determine the stability of the catalyst demonstrated that no deactivation in experimental runs of more than 17 h occurred. Additionally a study of the catalyst after the reaction showed that only lowly structured carbonaceous species were formed on the catalyst surface, which is not expected to inhibit strongly the initial catalytic activity.     

Rhodium supported on thermally enhanced zeolite as catalysts for fuel reformation of jet fuels

Autothermal reformation of military jet fuel (1096 ppmw sulfur) was investigated with rhodium supported on thermally stabilized Y zeolite catalysts. The zeolite catalysts were thermally stabilized by ion exchanging with nitrate solutions of rare-earth metals (La, Ce, Sm, Gd, Dy and Er). Surface area analyses indicated that the exchanged zeolite could maintain its porous structure as high as 950 °C instead of 800 °C for a commercial NaY zeolite. The structure of the exchanged zeolite was characterized by X-ray diffraction (XRD). Rh-SmNaY zeolite reforming catalysts were prepared by incipient wetness and organometallic synthesis. The JP8 reforming experiments were performed in a short contact time adiabatic reactor with a monolithic catalyst with the addition of air and steam at a temperature below 920 °C. The effects of steam and fuel-to-air ratio (C/O ratio) were studied. Hydrogen and carbon monoxide were produced as the main products. Durability tests were performed with Rh/SmNaY-zeolite catalysts. This work shows that zeolite based catalysts can convert transportation fuels such as high sulfur jet fuel (over 1000 ppmw S) to syngas for solid oxide fuel cell applications.     

Adsorption of benzothiophene on Y zeolites investigated by infrared spectroscopy and flow calorimetry

Diffuse reflectance infrared spectra of benzothiophene adsorbed on different Y zeolites reveal that the cations and protons in the zeolites are the sites responsible for the adsorption of benzothiophene. On NaY, benzothiophene was molecularly adsorbed on the cations through the electrophilic interaction between the cations and the thiophenic rings. On the transition metal ion exchanged NiY and CuY zeolites, because of the presence of the d-electrons in the cations, the thiophenic rings interact with the cations to form the π-complexes through the σ–π electron donations. In the presence of hydroxyl species in the zeolites, the adsorbed sulfur compounds attach to the protons molecularly via the electrophilic interaction and undergo the opening of the thiophenic rings depending on the acidity of the zeolites and the adsorption amount. The apparent heat of adsorption of benzothiophene in normal octane on the Y zeolites determined by flow calorimetry shows that the adsorption strength based on the measured heat for each mole sulfur adsorbed on the Y zeolite is in the order of CuY > NiY > NaY  USY. For USY, due to the endothermic breakage of the thiophenic ring of benzothiophene induced by the acid sites of the zeolite, the apparent heat of adsorption is similar to that obtained from the adsorption on NaY. This work demonstrates that the transition metal ion exchanged zeolites exhibit excellent properties for sulfur adsorption because of the formation of the π-complexes and that the acidity of the zeolites is not advantageous for sulfur removal due to the strong adsorption and decomposition of the adsorbed species.