Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming

Megapores with spherical-like cells connected through windows and high porosities make up catalyst supports in the form of ceramic foams. These characteristics provide significant benefits for catalytic processes that are limited by mass or heat transport. This study focuses on the manufacture of ceramic foam using a polymeric sponge replica process and polymer foams as a template for catalyst supports, which are industrial waste from the packaging sector. To make ceramic foam catalysts, they were dipped in a catalyst solution, followed by a breakdown stage and a sintering process. Experiments focused on determinants that affect the desired characteristics of ceramic foams, such as the types of polymer foams that affect foam morphology, the rheology of catalyst solution that affects catalyst dispersion, and the polymer decomposition rate that affects catalytic performance during dry reforming of the methane process. The cell architectures of polyurethane and polyvinyl alcohol foams are attractive for catalyst support preparation because they have 98-99% porosity and typical cell sizes of 200 and 50 μm, respectively. The polyurethane performance was superior to the performance of polyvinyl alcohol in terms of higher porosity and better catalytic-solution absorption offering high catalyst active areas. The catalyst prepared from concentrated 10 wt % Ni/Al₂O₃-MgO (10NAM) slurry had the highest surface area (59.18 m²/g) and the highest metal oxide dispersion (5.65%). These results are relevant to the flow behavior of catalyst slurry which plays a key role in coating the catalyst gel on the polymer template. The thermal decomposition rate used to remove the polymer template from the catalyst structure is proportional to the ceramic foam structure (catalyst support structure). The slow decomposition rate bent and fractured foam-cell struts more than the faster rate. On the other hand, achieving good catalyst dispersion on catalyst supports necessitated a high sintering rate. When sintering was adjusted at a high sintering rate, the metal-particle dispersion was relatively high, around 7.44%, and the surface area of ceramic foam catalysts was 64.61 m²/g. Finally, the catalytic behavior toward hydrogen production through the dry reforming of methane using a fixed-bed reactor was evaluated under certain operating conditions.

Effects of alloying for steam or dry reforming of methane: a review of recent studies

A survey on the catalytic nature of Ni-based alloy catalysts in recent years provides a direction for future catalyst development.

The Influence of High-Energy Faceted TiO2 Supports on Co and Co-Ru Catalysts for Dry Methane Reforming

The reforming of methane from biogas has been proposed as a promising method of CO2 utilization.  Co-based catalysts are promising candidates for dry methane reforming. However, the main constraints limiting the large-scale use of Co-based catalysts are deactivation through carbon deposition (coking) and sintering due to weak metal-support interaction. We studied the structure-function properties and catalytic behavior of Co/TiO2 and Co-Ru/TiO2 catalysts using two different types of TiO2 supports, commercial TiO2 and faceted non-stoichiometric rutile TiO2 crystals (TiO2*). The Co and Ru metal particles were deposited on TiO2 supports using a wet-impregnation method with the percentage weight loading of Co and Ru of 5% and 0.5%, respectively. The materials were characterized using SEM, STEM-HAADF, XRD, XPS and BET. The catalytic performance was studied using the CH4:CO2 ratio of 3:2 to mimic the methane-rich biogas composition. Our results indicate that the addition of Ru to Co catalysts supported on TiO2* reduces carbon deposition and influences oxygen mobility. Co and Co-Ru catalysts supported on TiO2* has superior activity with the highest conversion of CO2 and CH4 of 34.7% and 23.5%, respectively. Despite the improved performance, the Co-Ru/TiO2* catalyst has limited stability due to the proliferation of nanoparticle growth and TiOx layers on the surface of the nanoparticles indicating the prevalence of the strong-metal support interaction.

Metal (Mo, W, Ti) Carbide Catalysts: Synthesis and Application as Alternative Catalysts for Dry Reforming of Hydrocarbons-A Review

Dry reforming of hydrocarbons (DRH) is a pro-environmental method for syngas production. It owes its pro-environmental character to the use of carbon dioxide, which is one of the main greenhouse gases. Currently used nickel catalysts on oxide supports suffer from rapid deactivation due to sintering of active metal particles or the deposition of carbon deposits blocking the flow of gases through the reaction tube. In this view, new alternative catalysts are highly sought after. Transition metal carbides (TMCs) can potentially replace traditional nickel catalysts due to their stability and activity in DR processes. The catalytic activity of carbides results from the synthesis-dependent structural properties of carbides. In this respect, this review presents the most important methods of titanium, molybdenum, and tungsten carbide synthesis and the influence of their properties on activity in catalyzing the reaction of methane with carbon dioxide.

Contribution of Oxide Supports in Nickel-Based Catalytic Elimination of Greenhouse Gases and Generation of Syngas

Carbon dioxide and/or dry methane reforming serves as an effective pathway to mitigate these greenhouse gases. This work evaluates different oxide supports including alumina, Y-zeolite and H-ZSM-5 zeolite for the catalysis of dry reforming methane with Nickel (Ni). The composite catalysts were prepared by impregnating the supports with Ni (5%) and followed by calcination. The zeolite supported catalysts exhibited more reducibility and basicity compared to the alumina supported catalysts, this was assessed with temperature programmed reduction using hydrogen and desorption using carbon dioxide. The catalytic activity, in terms of CH4 conversion, indicated that 5 wt% Ni supported on alumina exhibited higher CH4 conversion (80.5%) than when supported on Y-zeolite (71.8%) or H-ZSM-5 (78.5%). In contrast, the H-ZSM-5 catalyst led to higher CO2 conversion (87.3%) than Y-zeolite (68.4%) and alumina (83.9%) supported catalysts. The stability tests for 9 h time-on-stream showed that Ni supported with H-ZSM-5 had less deactivation (just 2%) due to carbon deposition. The characterization of spent catalysts using temperature programmed oxidation (O2-TPO), X-ray diffraction (XRD) and thermo-gravimetric analysis (TGA) revealed that carbon deposition was a main cause of deactivation and that it occurred in the lowest degree on the Ni H-ZSM-5 catalyst.

Thermocatalytic Hydrogen Production Through Decomposition of Methane-A Review

Consumption of fossil fuels, especially in transport and energy-dependent sectors, has led to large greenhouse gas production. Hydrogen is an exciting energy source that can serve our energy purposes and decrease toxic waste production. Decomposition of methane yields hydrogen devoid of COx components, thereby aiding as an eco-friendly approach towards large-scale hydrogen production. This review article is focused on hydrogen production through thermocatalytic methane decomposition (TMD) for hydrogen production. The thermodynamics of this approach has been highlighted. Various methods of hydrogen production from fossil fuels and renewable resources were discussed. Methods including steam methane reforming, partial oxidation of methane, auto thermal reforming, direct biomass gasification, thermal water splitting, methane pyrolysis, aqueous reforming, and coal gasification have been reported in this article. A detailed overview of the different types of catalysts available, the reasons behind their deactivation, and their possible regeneration methods were discussed. Finally, we presented the challenges and future perspectives for hydrogen production via TMD. This review concluded that among all catalysts, nickel, ruthenium and platinum-based catalysts show the highest activity and catalytic efficiency and gave carbon-free hydrogen products during the TMD process. However, their rapid deactivation at high temperatures still needs the attention of the scientific community.

Costa P, Hu C. Syngas Production via CO2 Reforming of Methane over Aluminum-Promoted NiO-10Al2O3-ZrO2 Catalyst

CO2 reforming of methane was studied at medium temperature (700 °C) using a GSHV of 48,000 h-1 over nickel catalysts supported on ZrO2 promoted by alumina. The catalysts were prepared by a one-step synthesis method and characterized by BET, H2-TPR, XRD, XPS, TEM, Raman spectroscopy, and TGA. The NiO-10Al2O3-ZrO2 catalyst exhibited higher catalytic performance in comparison with the NiO-ZrO2 catalyst. The enhancement of catalytic activity in dry reforming could be associated with the alterations in surface properties due to Al promotion. First, the Al promoter could modify the structure of ZrO2, leading to an increase of its pore volume and pore diameter. Second, the NiO-10Al2O3-ZrO2 catalyst exhibited high resistance to sintering. Third, the NiO-10Al2O3-ZrO2 catalyst showed high suppression to the loss of nickel during a long-term catalytic test. Finally, the addition of Al could inhibit the reduction of ZrO2 during the reduction and reaction, endowing further the stability.

Clay nanotube-metal core/shell catalysts for hydroprocesses

Catalytic hydroprocesses play a significant role in oil refining and petrochemistry. The tailored design of new metal nanosystems and optimization of their support, composition, and structure is a prospective strategy for enhancing the efficiency of catalysts. Mesoporous support impacts the active component by binding it to the surface, which leads to the formation of tiny highly dispersed catalytic particles stabilized from aggregation and with minimized leaching. The structural and acidic properties of the support are crucial and determine the size and dispersion of the active metal phase. Currently, research efforts are shifted toward the design of nanoscale porous materials, where homogeneous catalysts are displaced by heterogeneous. Ceramic materials, such as 50 nm diameter natural halloysite nanotubes, are of special interest for this. Much attention to halloysite clay is due to its tubular structure with a hollow 10-15 nm diameter internal cavity, textural characteristics, and different chemical compositions of the outer/inner surfaces, allowing selective nanotube modification. Loading halloysite with metal particles or placing them outside the tubes provides stable and efficient mesocatalysts. The low cost of this abundant nanoclay makes it a good choice for the scaled-up architectural design of core-shell catalysts, containing active metal sites (Au, Ag, Pt, Ru, Co, Mo, Fe₂O₃, CdS, CdZnS, Cu-Ni) located inside or outside the tubular template. These alumosilicate nanotubes are environment-friendly and are available in thousands of tons. Herein, we summarized the advances of halloysite-based composite materials for hydroprocesses, focusing on the selective binding of metal particles. We analyze the tubes' morphology adjustments and size selection, the physicochemical properties of pristine and modified halloysite (e.g., acid-etched or silanized), the methods of metal clusters formation, and their localization. We indicate prospective routes for the architectural design of stable and efficient nanocatalysts based on this safe and natural clay material.

Hydrogen Yield from CO2 Reforming of Methane: Impact of La2O3 Doping on Supported Ni Catalysts

Development of a transition metal based catalyst aiming at concomitant high activity and stability attributed to distinguished catalytic characteristics is considered as the bottleneck for dry reforming of methane (DRM). This work highlights the role of modifying zirconia (ZrO2) and alumina (Al2O3) supported nickel based catalysts using lanthanum oxide (La2O3) varying from 0 to 20 wt% during dry reforming of methane. The mesoporous catalysts with improved BET surface areas, improved dispersion, relatively lower reduction temperatures and enhanced surface basicity are identified after La2O3 doping. These factors have influenced the catalytic activity and higher hydrogen yields are found for La2O3 modified catalysts as compared to base catalysts (5 wt% Ni-ZrO2 and 5 wt% Ni-Al2O3). Post-reaction characterizations such as TGA have showed less coke formation over La2O3 modified samples. Raman spectra indicates decreased graphitization for La2O3 catalysts. The 5Ni-10La2O3-ZrO2 catalyst produced 80% hydrogen yields, 25% more than that of 5Ni-ZrO2. 5Ni-15La2O3-Al2O3 gave 84% hydrogen yields, 8% higher than that of 5Ni-Al2O3. Higher CO2 activity improved the surface carbon oxidation rate. From the study, the extent of La2O3 loading is dependent on the type of oxide support.

Nickel Phosphide Catalysts as Efficient Systems for CO2 Upgrading via Dry Reforming of Methane

This work establishes the primordial role played by the support’s nature when aimed at the constitution of Ni2P active phases for supported catalysts. Thus, carbon dioxide reforming of methane was studied over three novel Ni2P catalysts supported on Al2O3, CeO2 and SiO2-Al2O3 oxides. The catalytic performance, shown by the catalysts’ series, decreased according to the sequence: Ni2P/Al2O3 > Ni2P/CeO2 > Ni2P/SiO2-Al2O3. The depleted CO2 conversion rates discerned for the Ni2P/SiO2-Al2O3 sample were associated to the high sintering rates, large amounts of coke deposits and lower fractions of Ni2P constituted in the catalyst surface. The strong deactivation issues found for the Ni2P/CeO2 catalyst, which also exhibited small amounts of Ni2P species, were majorly associated to Ni oxidation issues. Along with lower surface areas, oxidation reactions might also affect the catalytic behaviour exhibited by the Ni2P/CeO2 sample. With the highest conversion rate and optimal stabilities, the excellent performance depicted by the Ni2P/Al2O3 catalyst was mostly related to the noticeable larger fractions of Ni2P species established.

Combined Syngas and Hydrogen Production using Gas Switching Technology

This paper focuses on the experimental demonstration of a three-stage GST (gas switching technology) process (fuel, steam/CO₂, and air stages) for syngas production from methane in the fuel stage and H₂/CO production in the steam/CO₂ stage using a lanthanum-based oxygen carrier (La_0.85Sr_0.15Fe_0.95Al_0.05O₃). Experiments were performed at temperatures between 750–950 °C and pressures up to 5 bar. The results show that the oxygen carrier exhibits high selectivity to oxidizing methane to syngas at the fuel stage with improved process performance with increasing temperature although carbon deposition could not be avoided. Co-feeding CO₂ with CH₄ at the fuel stage reduced carbon deposition significantly, thus reducing the syngas H₂/CO molar ratio from 3.75 to 1 (at CO₂/CH₄ ratio of 1 at 950 °C and 1 bar). The reduced carbon deposition has maximized the purity of the H₂ produced in the consecutive steam stage thus increasing the process attractiveness for the combined production of syngas and pure hydrogen. Interestingly, the cofeeding of CO₂ with CH₄ at the fuel stage showed a stable syngas production over 12 hours continuously and maintained the H₂/CO ratio at almost unity, suggesting that the oxygen carrier was exposed to simultaneous partial oxidation of CH₄ with the lattice oxygen which was restored instantly by the incoming CO₂. Furthermore, the addition of steam to the fuel stage could tune up the H₂/CO ratio beyond 3 without carbon deposition at H₂O/CH₄ ratio of 1 at 950 °C and 1 bar; making the syngas from gas switching partial oxidation suitable for different downstream processes, for example, gas-to-liquid processes. The process was also demonstrated at higher pressures with over 70% fuel conversion achieved at 5 bar and 950 °C.

Bimetallic nanocatalysts supported on graphitic carbon nitride for sustainable energy development: the shape-structure-activity relation

The catalytic performance of metal nanoparticles (NPs), including activity, selectivity, and durability, depends on their shape and structure at the molecular level. Consequently, metal NPs of different size and shape, e.g., nanobelts, nanocubes, nanoflakes, and nanowires, demonstrate different reactivity and provide different reaction rates depending on the facet exposed. In this context, the present review aims to summarize the shape-structure-activity relation of metallic nanocatalysts. Moreover, keeping in mind that the application of noble metal catalysts is expensive, we would like to draw the reader's attention to bimetallic nanocatalysts supported on graphitic carbon nitride. One of the advantages of these systems is the possibility to minimize the use of noble metals by introducing another metal either to the parent NPs and/or modifying the support materials. The development and optimization of bimetallic nanocatalysts might provide the new class of materials with superior, tunable performance, thermal stability and reduced costs compared to presently available commercial catalysts. Therefore, further application of these bimetallic composites for sustainable development in energy, green chemicals/fuels and environmental protection will be discussed.

Sepiolite-based adsorbents for carbon dioxide capture

Sepiolite and the sepiolite-based materials were studied in terms of carbon dioxide adsorption. The pore structure and the surface characterization of the obtained materials were specified based on adsorption-desorption isotherms of nitrogen measured at –196oC and carbon dioxide at 0oC. The specific surface area (SSA) was calculated according to the BET equation. The pore volume was estimated using the DFT method. Pristine sepiolite has shown the following value of SSA and CO2 uptake at 0oC – 105 m2/g and 0.27 mmol/g, respectively. The highest value of these parameters was found for material obtained by KOH activation of mixture sepiolite and molasses (MSEP2) – 676 m2/g and 1.49 mmol/g. Sample MSEP2 also indicated the highest value of total pore volume and micropores volume with a diameter up to 0.8 nm.

Metal-Support Interactions and C1 Chemistry: Transforming Pt-CeO2 into a Highly Active and Stable Catalyst for the Conversion of Carbon Dioxide and Methane

There is an ongoing search for materials which can accomplish the activation of two dangerous greenhouse gases like carbon dioxide and methane. In the area of C1 chemistry, the reaction between CO₂ and CH₄ to produce syngas (CO/H₂), known as methane dry reforming (MDR), is attracting a lot of interest due to its green nature. On Pt(111), high temperatures must be used to activate the reactants, leading to a substantial deposition of carbon which makes this metal surface useless for the MDR process. In this study, we show that strong metal–support interactions present in Pt/CeO₂(111) and Pt/CeO₂ powders lead to systems which can bind CO₂ and CH₄ well at room temperature and are excellent and stable catalysts for the MDR process at moderate temperature (500 °C). The behavior of these systems was studied using a combination of in situ/operando methods (AP-XPS, XRD, and XAFS) which pointed to an active Pt-CeO_2-x interface. In this interface, the oxide is far from being a passive spectator. It modifies the chemical properties of Pt, facilitating improved methane dissociation, and is directly involved in the adsorption and dissociation of CO₂ making the MDR catalytic cycle possible. A comparison of the benefits gained by the use of an effective metal-oxide interface and those obtained by plain bimetallic bonding indicates that the former is much more important when optimizing the C1 chemistry associated with CO₂ and CH₄ conversion. The presence of elements with a different chemical nature at the metal-oxide interface opens the possibility for truly cooperative interactions in the activation of C–O and C–H bonds.

Promoting dry reforming of methane via bifunctional NiO/dolomite catalysts for production of hydrogen-rich syngas

Extensive effort has been focused on the advancement of an efficient catalyst for CO2 reforming of CH4 to achieve optimum catalytic activity together with cost-effectiveness and high resistance to catalyst deactivation. In this study, for the first time, a new catalytic support/catalyst system of bifunctional NiO/dolomite has been synthesized by a wet impregnation method using low-cost materials, and it shows unique performance in terms of amphoteric sites and self-reduction properties. The catalysts were loaded into a continuous micro-reactor equipped with an online GC-TCD system. The reaction was carried out with a gas mixture consisting of CH4 and CO2 in the ratio of 1 : 1 flowing 30 ml min-1 at 800 °C for 10 h. The physicochemical properties of the synthesized catalysts were determined by various methods including X-ray diffraction (XRD), N2 adsorption-desorption, H2 temperature-programmed reduction (H2-TPR), temperature-programmed desorption of CO2 (TPD-CO2), and temperature-programmed desorption of NH3 (TPD-NH3). The highest catalytic performance of the DRM reaction was shown by the 10% NiO/dolomite catalyst (CH4 & CO2 conversion, χCH4; χCO2 ∼ 98% and H2 selectivity, S H2 = 75%; H2/CO ∼ 1 : 1 respectively). Bifunctional properties of amphoteric sites on the catalyst and self-reduction behaviour of the NiO/dolomite catalyst improved dry reforming of the CH4 process by enhancing CH4 and CO2 conversion without involving a catalyst reduction step, and the catalyst was constantly active for more than 10 h.

Mechanistic insights into the dominant reaction route and catalyst deactivation in biogas reforming using ab initio microkinetic modeling

Co and Ru are proposed as two possible catalyst candidates for the biogas reforming process as these convert most of the CH₄ to CO and yield less coke.

Molecular mechanisms of methane dry reforming on Co3Mo3N catalyst with dual sites

With density functional theory and microkinetic modeling, mechanisms responsible for the promoted dry reforming of methane (DRM) reactivity and coke resistance on the dual-site Co₃Mo₃N(111) surface are explained.

The Effects of CeO2 and Co Doping on the Properties and the Performance of the Ni/Al2O3-MgO Catalyst for the Combined Steam and CO2 Reforming of Methane Using Ultra-Low Steam to Carbon Ratio

In this paper, the 10 wt% Ni/Al2O3-MgO (10Ni/MA), 5 wt% Ni-5 wt% Ce/Al2O3-MgO (5Ni5Ce/MA), and 5 wt% Ni-5 wt% Co/Al2O3-MgO (5Ni5Co/MA) catalysts were prepared by an impregnation method. The effects of CeO2 and Co doping on the physicochemical properties of the Ni/Al2O3-MgO catalyst were comprehensively studied by N2 adsorption-desorption, X-ray diffraction (XRD), transmission electron microscopy (TEM), H2 temperature programmed reduction (H2-TPR), CO2 temperature programmed reduction (CO2-TPD), and thermogravimetric analysis (TGA). The effects on catalytic performance for the combined steam and CO2 reforming of methane with the low steam-to-carbon ratio (S/C ratio) were evaluated at 620 °C under atmospheric pressure. The appearance of CeO2 and Co enhanced the oxygen species at the surface that decreased the coke deposits from 17% for the Ni/MA catalyst to 11–12% for the 5Ni5Ce/MA and 5Ni5Co/MA catalysts. The oxygen vacancies in the 5Ni5Ce/MA catalyst promoted water activation and dissociation, producing surface oxygen with a relatively high H2/CO ratio (1.6). With the relatively low H2/CO ratio (1.3), the oxygen species at the surface was enhanced by CO2 activation-dissociation via the redox potential in the 5Ni5Co/MA catalyst. The improvement of H2O and CO2 dissociative adsorption allowed the 5Ni5Ce/MA and 5Ni5Co/MA catalysts to resist the carbon formation, requiring only a low amount of steam to be added.

High Channel Density Ceramic Microchannel Reactor for Syngas Production

Solid oxide fuel cells can operate with carbonaceous fuels, such as syngas, biogas, and methane, using either internal or external reforming, and they represent a more efficient alternative to internal combustion engines. In this work, we explore, for the first time, an alumina membrane containing straight, highly packed (461,289 cpsi), parallel channels of a few micrometers (21 µm) in diameter as a microreformer. As a model reaction to test the performance of this membrane, the dry reforming of methane was carried out using nickel metal and a composite nickel/ceria as catalysts. The samples with intact microchannels were more resistant to carbon deposition than those with a powdered sample, highlighting the deactivation mitigation effect of the microchannel structure. The coke content in the microchannel membrane was one order of magnitude lower than in the powder catalyst. Overall, this work is a proof of concept on the use of composite alumina membrane as microchannel reactors for high temperature reactions.

Combined Reforming of Clean Biogas over Nanosized Ni–Rh Bimetallic Clusters

The combined steam/dry reforming of clean biogas (CH4/CO2 = 50/50 v/v) represents an innovative way to produce synthesis gas (CO + H2) using renewable feeds, avoiding to deplete the fossil resources and increase CO2 pollution. The reaction was carried out to optimize the reaction conditions for the production of a syngas with a H2/CO ratio suitable for the production of methanol or fuels without any further upgrading. Ni-Rh/Mg/Al/O catalysts obtained from hydrotalcite-type precursors showed high performances in terms of clean biogas conversion due to the formation of very active and resistant Ni-Rh bimetallic nanoparticles. Through the utilization of a {Ni10Rh(CO)19}{(CH3CH2)4N}3 cluster as a precursor of the active particles, it was possible to promote the Ni-Rh interaction and thus obtain low metal loading catalysts composed by highly dispersed bimetallic nanoparticles supported on the MgO, MgAl2O4 matrix. The optimization of the catalytic formulation improved the size and the distribution of the active sites, leading to a better catalyst activity and stability, with low carbon deposition with time-on-stream.