Partial oxidation of methane to CO and H2 over nickel and/or cobalt containing ZrO2, ThO2, UO2, TiO2 and SiO2 catalysts

The influence of different metal oxide supports (i.e. ZrO₂, ThO₂, UO₂, TiO₂ and SiO₂) on the performance of Ni- and/or Co-containing catalysts Ni and/or Co/MO₂ mole ratio (where M=Zr, Th, U, Ti or Si)=1.0] in the oxidative methane-to-syngas conversion at very low contact time (GHSV=5.2×10⁵ cm³ g⁻¹ h⁻¹ at STP) was investigated. The nickel-containing ZrO₂, ThO₂ and UO₂ catalysts (with or without pre-reduction by hydrogen at 500°C) showed good performance in the process; the order of their performance is NiO–ThO₂>NiO–UO₂>NiO–ZrO₂. The NiO–TiO₂ showed appreciable catalytic activity only after its reduction at 800°C. However, this catalyst and the NiO–SiO₂ catalyst showed poor performance in the process. These two catalysts are also deactivated very fast, mostly because of sintering of Ni and/or formation of catalytically inactive binary metal oxide phases by solid–solid reaction at the high catalyst calcination and/or catalytic reaction temperature. Although the Ni-containing ThO₂, UO₂ and ZrO₂ catalysts showed good performance, carbon deposition on them during the process is fast. However, because of the addition of cobalt to these catalysts (with Co/Ni=1.0), the rate of carbon deposition on them in the process is drastically reduced. This Co addition however resulted in a significant decrease in both the conversion and selectivity; the decrease in the selectivity was small.