Unbounding the Future: Designing NiAl-Based Catalysts for Dry Reforming of Methane

Dry reforming of methane (DRM), the catalytic conversion of CH4 and CO2 into syngas (H2+CO), is an important process closely correlated to the environment and chemical industry. NiAl-based catalysts have been reported to exhibit excellent activity, low cost, and environmental friendliness. At the same time, the rapid deactivation caused by carbon deposition, Ni sintering, and phase transformation exerts great challenges for its large-scale applications. This review summarizes the recent advances in NiAl-based catalysts for DRM, particularly focusing on the strategies to construct efficient and stable NiAl-based catalysts. Firstly, the thermodynamics and elementary steps of DRM, including the activation of reactants and coke formation and elimination, are summarized. The roles of Al2O3 and its mixed oxides as the support, and the influences of the promoters employed in NiAl-based catalysts over the DRM performance, are then illustrated. Finally, the design of anti-coking and anti-sintering NiAl-based catalysts for DRM is suggested as feasible and promising by tailoring the structure and states of Ni and the modification of Al-based supports including small Ni size, high Ni dispersion, proper basicity, strong metal-support interaction (SMSI), active oxygen species as well as high phase stability.

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.

Thermal Reactions of NiAl3O6+ and Al4O6+ with Methane: Reactivity Enhancement by Doping

Investigation of the reactivity of heteronuclear metal oxide clusters is an important way to uncover the molecular-level mechanisms of the doping effect. Herein, we performed a comparative study on the reactions of CH4 with NiAl3O6+ and Al4O6+ cluster cations at room temperature to understand the role of Ni during the activation and transformation of methane. Mass spectrometric experiments identify that both NiAl3O6+ and Al4O6+ could bring about hydrogen atom abstraction reaction to generate CH3• radical; however, only NiAl3O6+ has the potential to stabilize [CH3] moiety and then transform [CH3] to CH2O. Density functional theory calculations demonstrate that the terminal oxygen radicals (Ot-•) bound to Al act as the reactive sites for the two clusters to activate the first C-H bond. Although the Ni atom cannot directly participate in methane activation, it can manipulate the electronic environment of the surrounding bridging oxygen atoms (Ob) and enable such Ob to function as an electron reservoir to help Ot-• oxidize CH4 to [H-O-CH3]. The facile reduction of Ni3+ to Ni+ also facilitates the subsequent step of activating the second C-H bond by the bridging "lattice oxygen" (Ob2-), finally enabling the oxidation of methane into formaldehyde. The important role of the dopant Ni played in improving the product selectivity of CH2O for methane conversion discovered in this study allows us to have a possible molecule-level understanding of the excellent performance of the catalysts doping with nickel.

Assessing the effect of acid and alkali treatment on a halloysite-based catalyst for dry reforming of methane

Dry reforming of methane (DRM) has recently received wide attention owing to its outstanding performance in the reduction and conversion of CH4 and CO2 to syngas (H2 and CO). From an industrial perspective, nickel (Ni)-supported catalysts have been deemed among the most suitable catalysts for DRM owing to their low cost and high activity compared to noble metals. However, a downside of nickel catalysts is their high susceptibility to deactivation due to coke formation and sintering at high temperatures. Using appropriate supports and preparation methods plays a major role in improving the activity and stability of Ni-supported catalysts. Halloysite nanotubes (HNTs) are largely utilized in catalysis as a support for Ni owing to their abundance, low cost, and ease of preparation. The treatment of HNTs (chemical or physical) prior to doping with Ni is considered a suitable method for increasing the overall performance of the catalyst. In this study, the surface of HNTs was activated with acids (HNO3 and H2SO4) and alkalis (NaOH and Na2CO3 + NaNO3) prior to Ni doping to assess the effects of support treatment on the stability, activity, and longevity of the catalyst. Nickel catalysts on raw HNT, acid-treated HNT, and alkali-treated HNT supports were prepared via wet impregnation. A detailed characterization of the catalysts was conducted using X-ray diffraction (XRD), BET surface area analysis, scanning electron microscopy (SEM), transmission electron microscopy (TEM), solid-state nuclear magnetic resonance (ssNMR), H2-temperature programmed reduction, (H2-TPR), CO2-temperature programmed desorption (CO2-TPD), and Ni-dispersion via H2-pulse chemisorption. Our results reveal a clear alteration in the structure of HNTs after treatment, while elemental mapping shows a uniform distribution of Ni throughout all the different supports. Moreover, the supports treated with a molten salt method resulted in the overall highest CO2 and CH4 conversion among the studied catalysts and exhibited high stability over 24 hours testing.

Direct methane protonic ceramic fuel cells with self-assembled Ni-Rh bimetallic catalyst

Direct methane protonic ceramic fuel cells are promising electrochemical devices that address the technical and economic challenges of conventional ceramic fuel cells. However, Ni, a catalyst of protonic ceramic fuel cells exhibits sluggish reaction kinetics for CH4 conversion and a low tolerance against carbon-coking, limiting its wider applications. Herein, we introduce a self-assembled Ni-Rh bimetallic catalyst that exhibits a significantly high CH4 conversion and carbon-coking tolerance. It enables direct methane protonic ceramic fuel cells to operate with a high maximum power density of ~0.50 W·cm-2 at 500 °C, surpassing all other previously reported values from direct methane protonic ceramic fuel cells and even solid oxide fuel cells. Moreover, it allows stable operation with a degradation rate of 0.02%·h-1 at 500 °C over 500 h, which is ~20-fold lower than that of conventional protonic ceramic fuel cells (0.4%·h-1). High-resolution in-situ surface characterization techniques reveal that high-water interaction on the Ni-Rh surface facilitates the carbon cleaning process, enabling sustainable long-term operation.

Biogas Upgrading by CO2 Methanation with Ni-, Ni–Fe-, and Ru-Based Catalysts

This piece of work dealt with the concept of ‘biogas upgrading’ or enrichment of the CH4 contained in a sweetened biogas to proportions and features comparable to those of synthetic natural gas (SNG). For this, the behavior of three lab made catalysts (Ni/Al2O3, Ru/Al2O3, and Ni–Fe/Al2O3) was tested in a CO2 methanation reaction (Sabatier reaction) under different feeding conditions (with and without methane). In the first set of experiments (without methane), the good catalytic behavior of the solids was validated. All three catalysts offered similar and increasing CO2 conversions with increasing temperature (range studied from 250 to 400 °C) at a constant WHSV of 30 × 103 STPmL·gcat−1·h−1. The CH4 selectivity remained close to one in all cases. Considering their total metallic load, the Ru (3.7 wt%)-based catalyst stood out remarkably, with TOF values that reached up to 5.1 min−1, this being six or three times higher, than those obtained with the Ni (10.3 wt%) and Ni–Fe (7.4–2.1 wt%) catalysts, respectively. In the second set (cofeeding methane), and also for the three catalysts, a high correspondence between the conversions (and selectivities) obtained with both types of feeds was observed. This indicated that the addition of CH4 to the system did not severely modify the reaction mechanism, resulting in the possibility of taking advantage of the ‘biogas upgrading’ process by using H2 produced off-peak by electrolysis. In order to maximize the CH4 yield, temperatures in the range from 350–375 °C and a H2:CO2 molar ratio of 6:1 were determined as the optimal reaction conditions.

Synthesis of Catalytic Precursors Based on Mixed Ni-Al Oxides by Supercritical Antisolvent Co-Precipitation

Mixed Ni-Al oxide catalytic precursors with different elemental ratios (20, 50, and 80 wt.% Ni0) were synthesized using green supercritical antisolvent co-precipitation (SAS). The obtained oxide precursors and metal catalysts were characterized in detail by X-ray diffraction (XRD) analysis, atomic pair distribution function (PDF) analysis, CO adsorption, and high-resolution transmission electron microscopy (HRTEM). It was found that the composition and structure of the Ni-Al precursors are related to the Ni content. The mixed Ni1−xAlxO oxide with NiO-based crystal structure was formed in the Ni-enriched sample, whereas the highly dispersed NiAl2O4 spinel was observed in the Al-enriched sample. The obtained metal catalysts were tested in the process of anisole H2-free hydrogenation. 2-PrOH was used as a hydrogen donor. The catalyst with 50 wt.% Ni0 demonstrated the highest activity in the hydrogenation process.

Effect of Modified Alumina Support on the Performance of Ni-Based Catalysts for CO2 Reforming of Methane

The CO2 reforming of methane to syngas was examined over five different supported catalysts. In this study, 5% Ni was used as the active metal part of the catalyst. To better comprehend the impact of the supports on the catalytic properties, 5% Ni-based catalysts were characterized using nitrogen adsorption–desorption isotherms, XRD, H2-TPR, CO2-TPD, TGA, TPO, FTIR, and Raman. The results showed that the catalyst support with the highest surface area provided the best catalytic activity. The acquired CH4 and CO2 conversions at 700 °C were 58.2% and 67.6%, respectively, with a hydrogen/carbon ratio of 0.85. The TGA investigation of the high-surface-area sample produced a minimum carbon deposition of 11.2 wt.%, and in the CO2-TPD investigation, the high-surface-area sample exhibited the absence of a peak in the strong-basic-sites zone. The formation of NiAl2O4 spinel, moderate basicity, and the high surface area explained the outperformance of the high-surface-area catalyst sample.

Aqueous-Phase Glycerol Conversion over Ni-Based Catalysts Synthesized by Nanocasting

A morphological strategy consisting of nanocasting synthesis of nickel aluminate spinel precursor was addressed. Two nanocasted catalysts were synthesized involving different template-removal procedures (i.e., Teflon-assisted calcination vs. NaOH washing) for spinel recovery. As a reference, spinel NiAl2O4 supported by SBA-15 and bare nickel aluminate spinel were selected. The obtained solids were characterized in detail, examining their textural, acid–base, structural and compositional characteristics, either in the calcined or reduced forms. The as-obtained catalysts’ performance was evaluated in the aqueous-phase reforming of glycerol at 235 °C and 35 bar. Exhausted samples were also characterized to enlighten changes in catalyst properties during the aqueous-phase reaction. NiAl/SBA-15 and NiAl-NCF catalyst showed very poor catalytic performance for the glycerol transformation. NiAl-NCN catalyst presented improved activity with respect to NiAl, with a 20% higher hydrogen production rate but, as a drawback, higher methane formation for a whole range of glycerol conversions. Exhausted catalyst indicated nickel oxidized in liquid phase reaction.

Electrodeposition of a Li-Al Layered Double Hydroxide (LDH) on a Ball-like Aluminum Lathe Waste Strips in Structured Catalytic Applications: Preparation and Characterization of Ni-Based LDH Catalysts for Hydrogen Evolution

A functionally structured catalyst was explored for ethanol steam reforming (ESR) to generate H2. Aluminum lathe waste strips were employed as the structured catalytic framework. The mixed metal oxide (Li-Al-O) was formed on the surface of Al lathe waste strips through calcination of the Li-Al-CO3 layered double hydroxide (LDH), working as the support for the formation of Ni catalyst nanoparticles. NaOH and NaHCO3 titration solutions were, respectively, used for adjusting the pH of the NiCl2 aqueous solutions at 50 °C when developing the precursors of the Ni-based catalysts forming in-situ on the Li-Al-O oxide support. The Ni precursor on the Al structured framework was reduced in a H2 atmosphere at 500 °C for 3 h, changing the hydroxide precursor into Ni nanoparticles. The titration agent (NaOH or NaHCO3) effectively affected the physical and chemical characterizations of the catalyst obtained by the different titrations. The ESR reaction catalyzed by the structured catalysts at a relatively low temperature of 500 °C was studied. The catalyst using NaHCO3 titration presented good stability for generating H2 during ESR, achieving a high rate of H2 volume of about 122.9 L/(gcat·h). It also had a relatively low acidity on the surface of the Li-Al-O oxide support, leading to low activity for the dehydration of ethanol and high activity to H2 yield. The interactions of catalysts between the Ni precursors and the Li-Al-O oxide supports were discussed in the processes of the H2 reduction and the ESR reaction. Mechanisms of carbon formation during the ESR were proposed by the catalysts using NaOH and NaHCO3 titration agents.

Effect of preparation methods of CeO2 on the properties and performance of Ni/CeO2 in CO2 reforming of CH4

CO₂ reforming of CH₄ (CRM) is not only beneficial to environmental protection, but also valuable for industrial application. Different CeO₂ supports were prepared to investigate the matching between Ni and CeO₂ over Ni/CeO₂ and its effect on CRM. The physicochemical properties of Ni/CeO₂-C (commercial CeO₂), Ni/CeO₂-H (hydrothermal method) as well as Ni/CeO₂-P (precipitation method) were characterized by XRD, N₂ adsorption at − 196 °C, TEM, SEM–EDS, H₂-TPR, NH₃-TPD and XPS. Ni⁰ with good dispersion and CeO₂ with more oxygen vacancies were obtained on Ni/CeO₂-H, proving the influence on Ni/CeO₂ catalysts caused by the preparation methods of CeO₂. The initial conversion of both CO₂ and CH₄ of Ni/CeO₂-H was more than five times that of Ni/CeO₂-P and Ni/CeO₂-C. The better matching between Ni and CeO₂ on Ni/CeO₂-H was the reason for its best catalytic performance in comparison with the Ni/CeO₂-C and Ni/CeO₂-P samples.

Recent Advances in Catalysis for Methanation of CO2 from Biogas

Biogas, with its high carbon dioxide content (30–50 vol%), is an attractive feed for catalytic methanation with green hydrogen, and is suitable for establishing a closed carbon cycle with methane as energy carrier. The most important questions for direct biogas methanation are how the high methane content influences the methanation reaction and overall efficiency on one hand, and to what extent the methanation catalysts can be made more resistant to various sulfur-containing compounds in biogas on the other hand. Ni-based catalysts are the most favored for economic reasons. The interplay of active compounds, supports, and promoters is discussed regarding the potential for improving sulfur resistance. Several strategies are addressed and experimental studies are evaluated, to identify catalysts which might be suitable for these challenges. As several catalyst functionalities must be combined, materials with two active metals and binary oxide support seem to be the best approach to technically applicable solutions. The high methane content in biogas appears to have a measurable impact on equilibrium and therefore CO2 conversion. Depending on the initial CH4/CO2 ratio, this might lead to a product with higher methane content, and, after work-up, to a drop in-option for existing natural gas grids.

Coke-resistant Ni-based bimetallic catalysts for the dry reforming of methane: effects of indium on the Ni/Al2O3 catalyst

In the quest for highly efficient coke-resistant catalysts for the dry reforming of methane (DRM) to produce syngas, a series of Ni–In/γ-Al2O3 catalysts with various Ni contents were prepared via a “two-solvent” method and used for the DRM reaction.

Structural insight into an atomic layer deposition (ALD) grown Al2O3 layer on Ni/SiO2: impact on catalytic activity and stability in dry reforming of methane

The development of stable Ni-based dry reforming of methane (DRM) catalysts is a key challenge owing to the high operating temperatures of the process and the propensity of Ni for promoting carbon deposition. In this work, Al2O3-coated Ni/SiO2 catalysts have been developed by employing atomic layer deposition (ALD). The structure of the catalyst at each individual preparation step was characterized in detail through a combination of in situ XAS-XRD, ex situ 27Al NMR and Raman spectroscopy. Specifically, in the calcination step, the ALD-grown Al2O3 layer reacts with the SiO2 support and Ni, forming aluminosilicate and NiAl2O4. The Al2O3-coated Ni/SiO2 catalyst exhibits an improved stability for DRM when compared to the benchmark Ni/SiO2 and Ni/Al2O3 catalysts. In situ XAS-XRD during DRM together with ex situ Raman spectroscopy and TEM of the spent catalysts confirm that the ALD-grown Al2O3 layer suppresses the sintering of Ni, in turn reducing also coke formation significantly. In addition, the formation of an amorphous aluminosilicate phase by the reaction of the ALD-grown Al2O3 layer with the SiO2 support inhibited catalysts deactivation via NiAl2O4 formation, in contrast to the reference Ni/Al2O3 system. The in-depth structural characterization of the catalysts provided an insight into the structural dynamics of the ALD-grown Al2O3 layer, which reacts both with the support and the active metal, allowing to rationalize the high stability of the catalyst under the harsh DRM conditions.

Synthesis of Ni/NiAlOx Catalysts for Hydrogenation Saturation of Phenanthrene

The saturation of octahydrophenanthrene was the rate-determining step in the hydrogenation process from phenanthrene to perhydrophenanthrene, which was due to the steric hindrance and competitive adsorption of octahydrophenanthrene. In this work, a series of Ni/NiAlO_x catalysts with a uniform electron-deficient state of Ni derived from the nickel aluminate structure was synthesized to overcome the disadvantage of noble catalyst and the traditional sulfided catalysts in the saturation hydrogenation process of phenanthrene. Results showed that the catalyst calcinated at 650°C possessed more Ni²⁺ (∼98%) occupying octahedral sites and exhibited the highest r_obs (1.53 × 10^-3 mol kg^-1 s^-1) and TOF (14.64 × 10^-3 s^-1) for phenanthrene hydrogenation. Furthermore, its ability to overcome steric hindrance and promote the rate-determining step was proven by octahydrophenanthrene hydrogenation. Comparing the evolution of hydrogenation activity with the change in the electronic structure of surface Ni sites, it was shown that the increase of metallic electron deficiency hindered the π-back bonding between surface Ni and aromatic rings, which was unfavorable for aromatic adsorption. As a result, the phenanthrene hydrogenation saturation performance can be enhanced by stabilizing the electron-deficient state of surface Ni on an optimal degree.

Anti-Coking and Anti-Sintering Ni/Al2O3 Catalysts in the Dry Reforming of Methane: Recent Progress and Prospects

Coking and metal sintering are limitations of large-scale applications of Ni/Al2O3 catalysts in DRM reactions. In this review, several modification strategies to enhance the anti-deactivation property of Ni/Al2O3 are proposed and discussed with the recently developed catalyst systems, including structure and morphology control, surface acidity/basicity, interfacial engineering and oxygen defects. In addition, the structure–performance relationship and deactivation/anti-deactivation mechanisms are illustrated in depth, followed by prospects for future work.

The Effect of ZrO2 as Different Components of Ni-Based Catalysts for CO2 Reforming of Methane and Combined Steam and CO2 Reforming of Methane on Catalytic Performance with Coke Formation

The role of ZrO2 as different components in Ni-based catalysts for CO2 reforming of methane (CRM) has been investigated. The 10 wt.% Ni supported catalysts were prepared with ZrO2 as a support using a co-impregnation method. As a promoter (1 wt.% ZrO2) and a coactive component (10 wt.% ZrO2), the catalysts with ZrO2 were synthesized using a co-impregnation method. To evaluate the effect of the interaction, the Ni catalyst with ZrO2 as a coactive component was prepared by a sequential impregnation method. The results revealed that the activity, the selectivity, and the anti-coking ability of the catalyst depend upon the ZrO2 content, the Ni-ZrO2 interaction, basicity, and oxygen mobility of each catalyst resulting in different Ni dispersion and oxygen transfer pathway from ZrO2 to Ni. According to the characterization and catalytic activation results, the Ni catalyst with low ZrO2 content (as a promoter) presented highest selectivity toward CO owning to the high number of weak and moderate basic sites that enhance the CO2 activation-dissociation. The lowest activity (CH4 conversion ≈ 40% and CO2 conversion ≈ 39%) with the relatively high quantity of total coke formation (the weight loss of the spent catalyst in TGA curve ≈ 22%) of the Ni catalyst with ZrO2 as a support is ascribed to the lowest Ni dispersion due to the poor Ni-ZrO2 interaction and less oxygen transfer from ZrO2 to the deposited carbon on the Ni surface. The effect of a poor Ni-ZrO2 interaction on the catalytic activity was deducted by decreasing ZrO2 content to 10 wt.% (as a coactive component) and 1 wt.% (as a promoter). Although Ni catalysts with 1 wt.% and 10 wt.% ZrO2 provided similar oxygen mobility, the lack of oxygen transfer to coke during CRM process on the Ni surface was still indicated by the growth of carbon filament when the catalyst was prepared by co-impregnation method. When the catalyst was prepared by a sequential impregnation, the intimate interaction of Ni and ZrO2 for oxygen transfer was successfully developed through a ZrO2-Al2O3 composite. The interaction in this catalyst enhanced the catalytic activity (CH4 conversion ≈ 54% and CO2 conversion ≈ 50%) and the oxygen transport for carbon oxidation (the weight loss of the spent catalyst in TGA curve ≈ 7%) for CRM process. The Ni supported catalysts with ZrO2 as a promoter prepared by co-impregnation and with ZrO2 as a coactive component prepared by a sequential impregnation were tested in combined steam and CO2 reforming of methane (CSCRM). The results revealed that the ZrO2 promoter provided a greater carbon resistance (coke = 1.213 mmol·g−1) with the subtraction of CH4 and CO2 activities (CH4 conversion ≈ 28% and CO2 conversion ≈ %) due to the loss of active sites to the H2O activation-dissociation. Thus, the H2O activation-dissociation was promoted more efficiently on the basic sites than on the vacancy sites in CSCRM.

Coking-resistant dry reforming of methane over Ni/γ-Al2O3 catalysts by rationally steering metal-support interaction

The coking issue is the main challenge for dry reforming of methane (DRM) over Ni-based catalysts. Herein, we excavate the reasons for the enhanced coking resistance of the bounded Ni over the free state Ni in Ni/γ-Al₂O₃ catalysts for DRM. Rational metal-support interaction of the bounded Ni would facilitate desorption of CO, thus suppressing CO disproportionation and decreasing carbon deposition. The higher activity of the bounded Ni is ascribed to better methane cracking ability, stronger adsorption, and activation of CO₂ by forming polydentate carbonate. The better activation of CO₂ over the bounded Ni would also contribute to the gasification of formed coke. We gain an insight into the anti-coking mechanism of DRM determined by metal-support interaction in Ni/γ-Al₂O₃ catalysts through mechanistic studies. It is believed that our findings would enlighten the design of more efficient catalysts for DRM.

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The anti-coking ability of the bounded Ni is better than the free state Ni

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The bounded Ni has a stronger ability to activate CO₂ to produce active O∗ species

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High reactivity and stable polydentate carbonate enables efficient reaction

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Rational metal-support interaction results in good resistance to CO poisoning

Performance Analysis of TiO2-Modified Co/MgAl2O4 Catalyst for Dry Reforming of Methane in a Fixed Bed Reactor for Syngas (H2, CO) Production

Co/TiO2–MgAl2O4 was investigated in a fixed bed reactor for the dry reforming of methane (DRM) process. Co/TiO2–MgAl2O4 was prepared by modified co-precipitation, followed by the hydrothermal method. The active metal Co was loaded via the wetness impregnation method. The prepared catalyst was characterized by XRD, SEM, TGA, and FTIR. The performance of Co/TiO2–MgAl2O4 for the DRM process was investigated in a reactor with a temperature of 750 °C, a feed ratio (CO2/CH4) of 1, a catalyst loading of 0.5 g, and a feed flow rate of 20 mL min−1. The effect of support interaction with metal and the composite were studied for catalytic activity, the composite showing significantly improved results. Moreover, among the tested Co loadings, 5 wt% Co over the TiO2–MgAl2O4 composite shows the best catalytic performance. The 5%Co/TiO2–MgAl2O4 improved the CH4 and CO2 conversion by up to 70% and 80%, respectively, while the selectivity of H2 and CO improved to 43% and 46.5%, respectively. The achieved H2/CO ratio of 0.9 was due to the excess amount of CO produced because of the higher conversion rate of CO2 and the surface carbon reaction with oxygen species. Furthermore, in a time on stream (TOS) test, the catalyst exhibited 75 h of stability with significant catalytic activity. Catalyst potential lies in catalyst stability and performance results, thus encouraging the further investigation and use of the catalyst for the long-run DRM process.

Thermodynamic assessment of the stability of bulk and nanoparticulate cobalt and nickel during dry and steam reforming of methane

The high reaction temperatures during steam and dry reforming of methane inevitably entail catalyst deactivation. Evaluation of the feasibility or potentially relevant mechanisms at play is of utmost importance to develop highly active and stable catalysts. Herein, various oxidation reactions of bulk-sized nickel and cobalt to the corresponding metal oxide or in the presence of a metal oxide carrier are evaluated thermodynamically and linked to approximated conditions during methane reforming. In particular cobalt aluminate, as well as cobalt or nickel titanates are likely to form. As oxidation to bulk-sized metal oxide is unlikely, a thermodynamic analysis of metallic nanoparticles was performed to calculate the size dependent stability against oxidation to nickel oxide or cobalt oxide in water and carbon dioxide-rich environments. The calculations indicate that nickel nanoparticles >3 nm and cobalt nanoparticles >10 nm are expected to withstand oxidation during steam and dry reforming of methane with stoichiometric feed compositions and methane conversion levels >10% at temperatures up to 1100 and 900 °C, respectively. Lastly, the reduced thermal stability of nanoparticles due to melting point suppression was assessed, leading to similar recommendations concerning minimum particle sizes.

Role of Mixed Oxides in Hydrogen Production through the Dry Reforming of Methane over Nickel Catalysts Supported on Modified γ-Al2O3

H2 production through dry reforming of methane (DRM) is a hot topic amidst growing environmental and atom-economy concerns. Loading Ni-based reducible mixed oxide systems onto a thermally stable support is a reliable approach for obtaining catalysts of good dispersion and high stability. Herein, NiO was dispersed over MOx-modified-γ-Al2O3 (M = Ti, Mo, Si, or W; x = 2 or 3) through incipient wetness impregnation followed by calcination. The obtained catalyst systems were characterized by infrared, ultraviolet–visible, and X-ray photoelectron spectroscopies, and H2 temperature-programmed reduction. The mentioned synthetic procedure afforded the proper nucleation of different NiO-containing mixed oxides and/or interacting-NiO species. With different modifiers, the interaction of NiO with the γ-Al2O3 support was found to change, the Ni2+ environment was reformed exclusively, and the tendency of NiO species to undergo reduction was modified greatly. Catalyst systems 5Ni3MAl (M = Si, W) comprised a variety of species, whereby NiO interacted with the modifier and the support (e.g., NiSiO3, NiAl2O4, and NiWO3). These two catalyst systems displayed equal efficiency, >70% H2 yield at 800 °C, and were thermally stable for up to 420 min on stream. 5Ni3SiAl catalyst regained nearly all its activity during regeneration for up to two cycles.

Toward development of single-atom ceramic catalysts for selective catalytic reduction of NO with NH3

Insertion of transition metal species into crystalline alumina at low temperatures is proposed to achieve the dispersion of these species at atomic level paired with exceptional textural properties. Precisely, MeAl₂O₄/γ-Al₂O₃ (Me = Mn, Fe, Co, Ni, and/or Cu) nanostructured ceramic catalysts were fabricated with ultra large mesopores (16-30 nm), and high specific surface area (180-290 m² g^-1) and pore volume (1.1-1.6 cm³ g^-1). These ceramics were applied as efficient catalysts for the selective catalytic reduction (SCR) of NO with NH₃, and their selectivity was discussed in terms of N₂O formation, an undesirable byproduct. The catalysts containing Fe, Cu, or Mn showed the highest activities, however, within different temperature ranges. Further tuning of the catalytic activity and selectivity was achieved by creating ceramic catalysts with mixed compositions, e.g., CuFe and MnFe. Upon insertion of the transition metal species into crystalline structure of alumina to maximize atom efficiency, the N₂O formation profile did not change significantly for all metal aluminates except MnAl₂O₄, indicating that these catalysts are suitable for SCR and selectively promote the reduction of NO.

Constructing Ni-based confinement catalysts with advanced performances toward the CO2 reforming of CH4: state-of-the-art review and perspectives

The concept of Ni-based confinement catalysts has been proposed and developed to address the challenge of the thermal sintering of metallic Ni active sites during CRM by the space and/or lattice confinement effects.

Promotional effect of magnesium oxide for a stable nickel-based catalyst in dry reforming of methane

The generation of synthesis gas (hydrogen and carbon monoxide mixture) from two global warming gases of carbon dioxide and methane via dry reforming is environmentally crucial and for the chemical industry as well. Herein, magnesium-promoted NiO supported on mesoporous zirconia, 5Ni/xMg–ZrO₂ (x = 0, 3, 5, 7 wt%) were prepared by wet impregnation method and then were tested for syngas production via dry reforming of methane. The reaction temperature at 800 °C was found more catalytically active than that at 700 °C due to the endothermic feature of reaction which promotes efficient CH₄ catalytic decomposition over Ni and Ni–Zr interface as confirmed by CH₄–TSPR experiment. NiO–MgO solid solution interacted with ZrO₂ support was found crucial and the reason for high CH₄ and CO₂ conversions. The highest catalyst stability of the 5Ni/3Mg–ZrO₂ catalyst was explained by the ability of CO₂ to partially oxidize the carbon deposit over the surface of the catalyst. A mole ratio of hydrogen to carbon monoxide near unity (H₂/CO ~ 1) was obtained over 5Ni/ZrO₂ and 5Ni/5Mg–ZrO₂, implying the important role of basic sites. Our approach opens doors for designing cheap and stable dry reforming catalysts from two potent greenhouse gases which could be of great interest for many industrial applications, including syngas production and other value-added chemicals.

Al2O3-Coated Ni/CeO2 nanoparticles as coke-resistant catalyst for dry reforming of methane

To mitigate catalyst deactivation during the dry reforming of methane, Ni/CeO₂ catalysts composed of monodisperse Ni nanoparticles supported on CeO₂ nanorods are designed and coated with Al₂O₃ layers by atomic layer deposition.

Reforming of methane with carbon dioxide over cerium oxide promoted nickel nanoparticles deposited on 4-channel hollow fibers by atomic layer deposition

CeO₂ can significantly enhance the catalytic performance of Ni/Al₂O₃ catalysts prepared by atomic layer deposition for dry reforming of methane.