Controlled Surface Segregation Leads to Efficient Coke-Resistant Nickel/Platinum Bimetallic Catalysts for the Dry Reforming of Methane

Structural Changes of Ni and Ni-Pt Methane Steam Reforming Catalysts During Activation, Reaction, and Deactivation Under Dynamic Reaction Conditions

Ni-based catalysts are the most widely used materials to produce H2 in large-scale methane steam reformers under stationary conditions. For domestic applications such as fuel cells, H2 production involves the exposure of the catalysts to more dynamic conditions due to the daily startup and shutdown operation mode, making Ni-based catalysts susceptible to oxidation and deactivation. In this context, we report a systematic investigation of the structural changes occurring for monometallic Ni/MgAlOx and bimetallic NiPt/MgAlOx catalysts during methane steam reforming under transient conditions, comprising catalyst activation, operation, and deactivation processes. Besides extensive catalytic tests, the samples prepared by incipient wetness impregnation were characterized by complementary methods, including N2-physisorption, X-ray diffraction, H2-temperature-programmed reduction, and electron microscopy. Next, the structure of the Ni and Pt species was monitored under reaction conditions using time and spatially resolved in situ/operando X-ray absorption spectroscopy. The results obtained show that before catalyst activation by H2-reduction, nickel diffuses into the support lattice and forms mixed oxides with magnesium. In the activated catalysts, Ni is present in the metallic state or alloyed with Pt. A clear beneficial effect of the noble metal addition was identified on both the activity and stability of the bimetallic NiPt/MgAlOx catalyst. In contrast, the pronounced oxidation and reincorporation of Ni into the support lattice were observed for the monometallic sample, and these catalyst deactivation effects are hindered in the bimetallic Ni-Pt catalyst. Overall, the outcome of our study not only helps in understanding the catalyst activation/deactivation processes at an atomic level but also provides the basis for the rational development of improved methane steam reforming catalysts.

Coke-Resistant Ni/CeZrO2 Catalysts for Dry Reforming of Methane to Produce Hydrogen-Rich Syngas

Dry reforming of methane was studied over high-ratio zirconia in ceria-zirconia-mixed oxide-supported Ni catalysts. The catalyst was synthesized using co-precipitation and impregnation methods. The effects of the catalyst support and Ni composition on the physicochemical characteristics and performance of the catalysts were investigated. Characterization of the physicochemical properties was conducted using X-ray diffraction (XRD), N2-physisorption, H2-TPR, and CO2-TPD. The results of the activity and stability evaluations of the synthesized catalysts over a period of 240 min at a temperature of 700 °C, atmospheric pressure, and WHSV of 60,000 mL g−1 h−1 showed that the 10%Ni/CeZrO2 catalyst exhibited the highest catalytic performance, with conversions of CH4 and CO2 up to 74% and 55%, respectively, being reached. The H2/CO ratio in the product was 1.4, which is higher than the stoichiometric ratio of 1, indicating a higher formation of H2. The spent catalysts showed minimal carbon deposition based on the thermo-gravimetry analysis, which was <0.01 gC/gcat, so carbon deposition could be neglected.

Designing Sites in Heterogeneous Catalysis: Are We Reaching Selectivities Competitive With Those of Homogeneous Catalysts?

A critical review of different prominent nanotechnologies adapted to catalysis is provided, with focus on how they contribute to the improvement of selectivity in heterogeneous catalysis. Ways to modify catalytic sites range from the use of the reversible or irreversible adsorption of molecular modifiers to the immobilization or tethering of homogeneous catalysts and the development of well-defined catalytic sites on solid surfaces. The latter covers methods for the dispersion of single-atom sites within solid supports as well as the use of complex nanostructures, and it includes the post-modification of materials via processes such as silylation and atomic layer deposition. All these methodologies exhibit both advantages and limitations, but all offer new avenues for the design of catalysts for specific applications. Because of the high cost of most nanotechnologies and the fact that the resulting materials may exhibit limited thermal or chemical stability, they may be best aimed at improving the selective synthesis of high value-added chemicals, to be incorporated in organic synthesis schemes, but other applications are being explored as well to address problems in energy production, for instance, and to design greener chemical processes. The details of each of these approaches are discussed, and representative examples are provided. We conclude with some general remarks on the future of this field.

Catalytic Upgrading of Clean Biogas to Synthesis Gas

Clean biogas, produced by anaerobic digestion of biomasses or organic wastes, is one of the most promising substitutes for natural gas. After its purification, it can be valorized through different reforming processes that convert CH4 and CO2 into synthesis gas (a mixture of CO and H2). However, these processes have many issues related to the harsh conditions of reaction used, the high carbon formation rate and the remarkable endothermicity of the reforming reactions. In this context, the use of the appropriate catalyst is of paramount importance to avoid deactivation, to deal with heat issues and mild reaction conditions and to attain an exploitable syngas composition. The development of a catalyst with high activity and stability can be achieved using different active phases, catalytic supports, promoters, preparation methods and catalyst configurations. In this paper, a review of the recent findings in biogas reforming is presented. The different elements that compose the catalytic system are systematically reviewed with particular attention on the new findings that allow to obtain catalysts with high activity, stability, and resistance towards carbon formation.

Mechanistic and multiscale aspects of thermo-catalytic CO2 conversion to C1 products

The increasing environmental concerns due to anthropogenic CO2 emissions have called for an alternate sustainable source to fulfill rising chemical and energy demands and reduce environmental problems. The thermo-catalytic activation and conversion of abundantly available CO2, a thermodynamically stable and kinetically inert molecule, can significantly pave the way to sustainably produce chemicals and fuels and mitigate the additional CO2 load. This can be done through comprehensive knowledge and understanding of catalyst behavior, reaction kinetics, and reactor design. This review aims to catalog and summarize the advances in the experimental and theoretical approaches for CO2 activation and conversion to C1 products via heterogeneous catalytic routes. To this aim, we analyze the current literature works describing experimental analyses (e.g., catalyst characterization and kinetics measurement) as well as computational studies (e.g., microkinetic modeling and first-principles calculations). The catalytic reactions of CO2 activation and conversion reviewed in detail are: (i) reverse water-gas shift (RWGS), (ii) CO2 methanation, (iii) CO2 hydrogenation to methanol, and (iv) dry reforming of methane (DRM). This review is divided into six sections. The first section provides an overview of the energy and environmental problems of our society, in which promising strategies and possible pathways to utilize anthropogenic CO2 are highlighted. In the second section, the discussion follows with the description of materials and mechanisms of the available thermo-catalytic processes for CO2 utilization. In the third section, the process of catalyst deactivation by coking is presented, and possible solutions to the problem are recommended based on experimental and theoretical literature works. In the fourth section, kinetic models are reviewed. In the fifth section, reaction technologies associated with the conversion of CO2 are described, and, finally, in the sixth section, concluding remarks and future directions are provided.

Exotic Long-Range Surface Reconstruction on La0.7Sr0.3MnO3 Thin Films

Due to an extremely diverse phase space, La_1-xSr_xMnO₃, as with other manganites, offers a wide range of tunability and applications including colossal magnetoresistance and use as spin-polarized electrodes. Here, we study an unprecedented, exotic surface reconstruction (6 × 6) in La_1-xSr_xMnO₃ (x = 0.3) observed via low-energy electron diffraction (LEED). Scanning tunneling microscopy (STM) shows the surface is relatively flat, with unit-cell step heights, and X-ray photoelectron spectroscopy (XPS) reveals a strong degree of Sr segregation at the surface. By combining electron diffraction and first-principles computations, we propose that the long-range surface reconstruction consists of a Sr-segregated surface with La (6 × 6) ordering. This study expands our understanding of manganite systems and underscores their ability to form interesting surface reconstructions, driven largely by cation segregation that can potentially be controlled for tuning surface ordering.

Theoretical study of surface segregation and ordering in Ni-based bimetallic surface alloys

Ni-based bimetallic materials are promising for a series of important heterogeneous catalytic reactions because of their low cost and potential high activity. In order to understand their catalytic performances in catalytic processes, it is important to know the structural properties of these bimetallic surfaces, including, in particular, how the guest metal is distributed in the nickle host at finite temperature. By using the cluster expansion model built on density-functional theory calculations, combined with Monte Carlo simulation, we study the segregation and ordering behaviors in several frequently studied Ni-based bimetallic catalysts NiX (X = Fe, Co, and Cu). We found that Ni tends to segregate to the top most layer of the surface in NiFe and NiCo, while Cu tends to segregate to the topmost layer of NiCu surfaces. NiCo and NiCu lose short-range order quickly as the temperature increases. Under low temperature, NiFe forms an ordered Ni₃Fe structure, which, however, disappears above 550 K because of the order-disorder transition. These findings can provide important information for the understanding of the stability and activity of Ni-based bimetallic catalysts at high temperatures.

First-principles theoretical study on dry reforming of methane over perfect and boron-vacancy-containing h-BN sheet-supported Ni catalysts

The entire reaction mechanism of the dry reforming of methane (DRM) as well as the competition processes over perfect and boron-vacancy-containing h-BN sheet-supported Ni-catalysts (labeled Ni2/h-BN and Ni2/h-BN-B-D) was studied by density functional theory calculations in the present work. Our calculation results show that B-defected h-BN strongly binds to the Ni2 active sites (i.e., shows a strong metal-support interaction (SMSI) character) due to the better electron transfer between Ni2 sites and the support. It was found that CH4 is easier to activate than molecular CO2. The activation of CO2 occurs on the surface of Ni2/h-BN through a direct route, whereas it is prone to follow a hydrogen-assisted path for Ni2/h-BN-B-D via the COOH* intermediate, and the results show that the oxidant O* is easily formed on the surface of Ni2/h-BN-B-D. It was also found that O* is the main oxidant agent for CHx* intermediates through the CH3-O oxidation mechanism. The reaction kinetic analysis indicated that the reverse water gas shift reaction (RWGS) is much more favorable than DRM (1.30 vs. 1.72 eV) over the Ni2/h-BN system, whereas the RWGS and DRM are comparable on Ni2/h-BN-B-D (1.77 vs. 1.66 eV), suggesting a high DRM activity on Ni2/h-BN-B-D. Moreover, neither methane cracking nor a Boudouard reaction to form C* species is thermodynamically and kinetically unfavorable over Ni2/h-BN-B-D; hence, Ni2/h-BN-B-D has strong resistance to carbon deposition. Compared to Ni(111), both Ni2/h-BN-B-D and Ni2/h-BN show strong resistance to carbon deposition. Our results provide a further mechanistic understanding of the DRM over an Ni-based catalyst through the SMSI characteristic and the SMSI favors strong resistance to carbon deposition.

Smart Designs of Anti-Coking and Anti-Sintering Ni-Based Catalysts for Dry Reforming of Methane: A Recent Review

Dry reforming of methane (DRM) reaction has drawn much interest due to the reduction of greenhouse gases and production of syngas. Coking and sintering have hindered the large-scale operations of Ni-based catalysts in DRM reactions at high temperatures. Smart designs of Ni-based catalysts are comprehensively summarized in fourth aspects: surface regulation, oxygen defects, interfacial engineering, and structural optimization. In each part, details of the designs and anti-deactivation mechanisms are elucidated, followed by a summary of the main points and the recommended strategies to improve the catalytic performance, energy efficiency, and utilization rate.

Overcoming immiscibility toward bimetallic catalyst library

Bimetallics are emerging as important materials that often exhibit distinct chemical properties from monometallics. However, there is limited access to homogeneously alloyed bimetallics because of the thermodynamic immiscibility of the constituent elements. Overcoming the inherent immiscibility in bimetallic systems would create a bimetallic library with unique properties. Here, we present a nonequilibrium synthesis strategy to address the immiscibility challenge in bimetallics. As a proof of concept, we synthesize a broad range of homogeneously alloyed Cu-based bimetallic nanoparticles regardless of the thermodynamic immiscibility. The nonequilibrated bimetallic nanoparticles are further investigated as electrocatalysts for carbon monoxide reduction at commercially relevant current densities (>100 mA cm^-2), in which Cu_0.9Ni_0.1 shows the highest multicarbon product Faradaic efficiency of ~76% with a current density of ~93 mA cm^-2. The ability to overcome thermodynamic immiscibility in multimetallic synthesis offers freedom to design and synthesize new functional nanomaterials with desired chemical compositions and catalytic properties.

Experimental Study on Dry Reforming of Biogas for Syngas Production over Ni-Based Catalysts

Syngas production from dry reforming of biogas (DRB) is studied experimentally in this work. Ni/Al₂O₃, Pt/Al₂O₃, and Pt-Ni/Al₂O₃ are used as catalysts to examine the effect of CO₂ content in biogas and H₂O addition on DRB performance for reaction temperatures in the 600-800 °C range. It is found that the bimetallic Pt-Ni catalyst exhibits the best activity and thermal stability among the three types of catalysts studied due to better carbon deposition resistance. Because CO₂ functions as the oxidant in combustion, CH₄ conversion is enhanced when the biogas contains more CO₂. One hundred percent CO₂ conversion can be reached for biogas containing a less amount of CO₂ at high temperatures. With H₂O addition in DRB, the steam reforming of methane (SRM) reaction is the dominant reaction, resulting in higher H₂ and CO yields with biogas containing lesser amounts of CO₂. However, lower CH₄ conversion and negative CO₂ conversion do result. With higher CO₂ content in the biogas, higher CH₄ and CO₂ conversions can be obtained. Lower yields of H₂ and CO are obtained due to less SRM dominance. With H₂O addition in biogas, the H₂/CO ratio with a value greater than 1 can be obtained from DRB. It is also found that the H₂/CO ratio with a value of 2.1 can be obtained for reactant composition with a molar ratio of CH₄/CO₂/H₂O = 1:0.25:1 and reaction temperature of 800 °C.

The Comparison between Single Atom Catalysis and Surface Organometallic Catalysis

Single atom catalysis (SAC) is a recent discipline of heterogeneous catalysis for which a single atom on a surface is able to carry out various catalytic reactions. A kind of revolution in heterogeneous catalysis by metals for which it was assumed that specific sites or defects of a nanoparticle were necessary to activate substrates in catalytic reactions. In another extreme of the spectrum, surface organometallic chemistry (SOMC), and, by extension, surface organometallic catalysis (SOMCat), have demonstrated that single atoms on a surface, but this time with specific ligands, could lead to a more predictive approach in heterogeneous catalysis. The predictive character of SOMCat was just the result of intuitive mechanisms derived from the elementary steps of molecular chemistry. This review article will compare the aspects of single atom catalysis and surface organometallic catalysis by considering several specific catalytic reactions, some of which exist for both fields, whereas others might see mutual overlap in the future. After a definition of both domains, a detailed approach of the methods, mostly modeling and spectroscopy, will be followed by a detailed analysis of catalytic reactions: hydrogenation, dehydrogenation, hydrogenolysis, oxidative dehydrogenation, alkane and cycloalkane metathesis, methane activation, metathetic oxidation, CO₂ activation to cyclic carbonates, imine metathesis, and selective catalytic reduction (SCR) reactions. A prospective resulting from present knowledge is showing the emergence of a new discipline from the overlap between the two areas.

Syngas production by partial oxidation of ethanol on PtNi/SiO2–CeO2 catalysts

Syngas production from the partial oxidation of (bio)ethanol (POE) was demonstrated.

Surface organometallic chemistry in heterogeneous catalysis

Surface organometallic chemistry has been reviewed with a special focus on environmentally relevant transformations (C–H activation, CO₂conversion, oxidation).

Tuning the Electrocatalytic Oxygen Reduction Reaction Activity and Stability of Shape-Controlled Pt-Ni Nanoparticles by Thermal Annealing - Elucidating the Surface Atomic Structural and Compositional Changes

Shape-controlled octahedral Pt-Ni alloy nanoparticles exhibit remarkably high activities for the electroreduction of molecular oxygen (oxygen reduction reaction, ORR), which makes them fuel-cell cathode catalysts with exceptional potential. To unfold their full and optimized catalytic activity and stability, however, the nano-octahedra require post-synthesis thermal treatments, which alter the surface atomic structure and composition of the crystal facets. Here, we address and strive to elucidate the underlying surface chemical processes using a combination of ex situ analytical techniques with in situ transmission electron microscopy (TEM), in situ X-ray diffraction (XRD), and in situ electrochemical Fourier transformed infrared (FTIR) experiments. We present a robust fundamental correlation between annealing temperature and catalytic activity, where a ∼25 times higher ORR activity than for commercial Pt/C (2.7 A mg_Pt^-1 at 0.9 V_RHE) was reproducibly observed upon annealing at 300 °C. The electrochemical stability, however, peaked out at the most severe heat treatments at 500 °C. Aberration-corrected scanning transmission electron microscopy and energy-dispersive X-ray spectroscopy (EDX) in combination with in situ electrochemical CO stripping/FTIR data revealed subtle, but important, differences in the formation and chemical nature of Pt-rich and Ni-rich surface domains in the octahedral (111) facets. Estimating trends in surface chemisorption energies from in situ electrochemical CO/FTIR investigations suggested that balanced annealing generates an optimal degree of Pt surface enrichment, while the others exhibited mostly Ni-rich facets. The insights from our study are quite generally valid and aid in developing suitable post-synthesis thermal treatments for other alloy nanocatalysts as well.

One-Pot Synthesis of Size- and Composition-Controlled Ni-Rich NiPt Alloy Nanoparticles in a Reverse Microemulsion System and Their Application

Bimetallic nanoparticles have been the subject of numerous research studies in the nanotechnology field, in particular for catalytic applications. Control of the size, morphology, and composition has become a key challenge due to the relationship between these parameters and the catalytic behavior of the particles in terms of activity, selectivity, and stability. Here, we present a one-pot air synthesis of 2 nm Ni₉Pt₁ nanoparticles with a narrow size distribution. Control of the size and composition of the alloy particles is achieved at ambient temperature, in the aqueous phase, by the simultaneous reduction of nickel and platinum precursors with hydrazine, using a reverse microemulsion system. After deposition on an alumina support, this Ni-rich nanoalloy exhibits unprecedented stability under the harsh conditions of methane dry reforming.

A Review on Bimetallic Nickel-Based Catalysts for CO2 Reforming of Methane

In recent years, CO₂ reforming of methane (dry reforming of methane, DRM) has become an attractive research area because it converts two major greenhouse gasses into syngas (CO and H₂ ), which can be directly used as fuel or feedstock for the chemical industry. Ni-based catalysts have been extensively used for DRM because of its low cost and good activity. A major concern with Ni-based catalysts in DRM is severe carbon deposition leading to catalyst deactivation, and a lot of effort has been put into the design and synthesis of stable Ni catalysts with high carbon resistance. One effective and practical strategy is to introduce a second metal to obtain bimetallic Ni-based catalysts. The synergistic effect between Ni and the second metal has been shown to increase the carbon resistance of the catalyst significantly. In this review, a detailed discussion on the development of bimetallic Ni-based catalysts for DRM including nickel alloyed with noble metals (Pt, Ru, Ir etc.) and transition metals (Co, Fe, Cu) is presented. Special emphasis has been provided on the underlying principles that lead to synergistic effects and enhance catalyst performance. Finally, an outlook is presented for the future development of Ni-based bimetallic catalysts.

Strategies for Carbon and Sulfur Tolerant Solid Oxide Fuel Cell Materials, Incorporating Lessons from Heterogeneous Catalysis

Solid oxide fuel cells (SOFCs) are a rapidly emerging energy technology for a low carbon world, providing high efficiency, potential to use carbonaceous fuels, and compatibility with carbon capture and storage. However, current state-of-the-art materials have low tolerance to sulfur, a common contaminant of many fuels, and are vulnerable to deactivation due to carbon deposition when using carbon-containing compounds. In this review, we first study the theoretical basis behind carbon and sulfur poisoning, before examining the strategies toward carbon and sulfur tolerance used so far in the SOFC literature. We then study the more extensive relevant heterogeneous catalysis literature for strategies and materials which could be incorporated into carbon and sulfur tolerant fuel cells.

Supported Ni catalyst on a natural halloysite derived silica–alumina composite oxide with unexpected coke-resistant stability for steam-CO2 dual reforming of methane

This work presents a facile and scalable approach for preparing robust supported Ni catalyst with unexpected catalytic stability with outstanding coke deposition and Ni-sintering resistance for steam-CO₂ dual reforming of methane to produce syngas.

Promotional effects of rare earth elements (Sc, Y, Ce, and Pr) on NiMgAl catalysts for dry reforming of methane

The promoting effects of rare earth elements on NiMgAl catalysts for dry reforming of methane were clarified.

Progress in Synthesis of Highly Active and Stable Nickel-Based Catalysts for Carbon Dioxide Reforming of Methane

In recent decades, rising anthropogenic greenhouse gas emissions (mainly CO2 and CH4 ) have increased alarm due to escalating effects of global warming. The dry carbon dioxide reforming of methane (DRM) reaction is a sustainable way to utilize these notorious greenhouse gases. This paper presents a review of recent progress in the development of nickel-based catalysts for the DRM reaction. The enviable low cost and wide availability of nickel compared with noble metals is the main reason for persistent research efforts in optimizing the synthesis of nickel-based catalysts. Important catalyst features for the rational design of a coke-resistant nickel-based nanocatalyst for the DRM reaction are also discussed. In addition, several innovative developments based on salient features for the stabilization of nickel nanocatalysts through various means (which include functionalization with precursors, synthesis by plasma treatment, stabilization/confinement on mesoporous/microporous/carbon supports, and the formation of metal oxides) are highlighted. The final part of this review covers major issues and proposed improvement strategies pertaining to the rational design of nickel-based catalysts with high activity and stability for the DRM reaction.

High-throughput assessment of catalyst stability during autothermal reforming of model biogas

A six parallel-flow reactor set-up was implemented to assess the long-term stability of Ni-based catalysts for autothermal reforming of model biogas.

Structured Ni catalysts on porous anodic alumina membranes for methane dry reforming: NiAl2O4 formation and characterization

This communication presents the successful design of a structured catalyst based on porous anodic alumina membranes for methane dry reforming.