Design of stable Ni/ZrO2 catalysts for dry reforming of methane

Dry Reforming of Methane on Ni/LaZrO2 Catalyst under External Electric Fields: A Combined First-Principles and Microkinetic Modeling Study

Dry reforming of methane (DRM) reaction has great potential in reducing the greenhouse effect and solving energy problems. Herein, the DRM reaction mechanism and activity on Ni16/LaZrO2 catalyst under electric fields were comprehensively investigated by combining density functional theory calculations with microkinetic modeling. The results showed that La doping increases the interaction between Ni and ZrO2 by Ni cluster transfer of more electrons. The adsorption strength of species followed the order Ni16/ZrO2 > Ni16/LaZrO2, which is consistent with the results for the d-band center but opposite to the metal-support interaction. The best DRM reaction path on Ni16/LaZrO2 was the CH2-O pathway, which is different from the CH-O pathway on Ni(111) and Ni16/ZrO2. Both positive and negative electric fields of strong and weak metal-support interactions reduced the energy barrier of DRM reaction. Importantly, our results showed that the more dispersed and smaller Ni12/LaZrO2 model by considering the dispersing effect induced by La doping, which displayed very different results from that of Ni16/LaZrO2: reduced the energy barrier for methane decomposition, thereby promoting DRM reaction activity. Microkinetic results showed that the carbon deposition behavior of DRM becomes weaker on Ni16/LaZrO2 due to the suppression of methane decomposition in the presence of La doping compared to Ni16/ZrO2, but the opposite result is obtained on Ni12/LaZrO2. The order of DRM reactivity was Ni16/LaZrO2 < Ni16/ZrO2 < Ni12/LaZrO2, which is consistent with the experiment observations. The conversion of methane and CO2 was higher in positive electric fields than in negative electric fields at low temperatures, but the results were opposite at high temperature. Negative electric fields can improve the carbon deposition resistance of Ni-based catalysts compared to positive electric fields. The degree of rate control analysis showed that CHx* oxidation also plays an important role in the DRM reaction. We envision that this study could provide a deeper understanding for guiding the widespread application of electric field catalysis.

Ni-Cu Alloy Nanoparticles Confined by Physical Encapsulation with SiO2 and Chemical Metal-Support Interaction with CeO2 for Methane Dry Reforming

Fabrication of sintering- and carbon-free Ni catalysts for methane dry reforming (MDR), which is attractive to upgrade greenhouse gases CH₄ and CO₂, is challenging. In this work, we innovatively synthesized Ni-Cu alloy nanoparticles confined by physical encapsulation and chemical metal-support interaction (MSI); the synergism of alloy effect, size effect, MSI, and confinement effect in the catalysts gave high rates of CH₄ and CO₂ of 6.98 and 7.16 mmol/(g_Nis), respectively, at 1023 K for 50 h. The rates were 2-3 times enhanced compared to those in the literature. XRD, TEM, H₂-TPR, and so forth revealed that the alloy effect, size effect, and MSI of Ni-Cu and CeO₂ enhanced the MDR activity; MSI promoted the ceria surface lattice oxygen mobility and generated more oxygen vacancies, almost completely gasifying carbon deposits; chemical confinement from MSI and physical confinement from SiO₂ nanospheres realized sintering-free alloys and CeO₂ nanoparticles. The synergistic approach provides a universal strategy for sintering- and carbon-free Ni catalyst design for MDR reaction.

Ab initio study of the adsorption properties of CO2 reduction intermediates: The effect of Ni5Ga3 alloy and the Ni5Ga3/ZrO2 interface

The Ni5Ga3 alloy supported on ZrO2 is a promising catalyst for the reduction of CO2 due to its higher selectivity to methanol at ambient pressure, e.g., activity comparable to industrial catalysts. However, our atomistic understanding of the role of the cooperative effects induced by the Ni5Ga3 alloy formation and its Ni5Ga3/ZrO2 interface in the CO2 reduction is still far from satisfactory. In this work, we tackle these questions by employing density functional theory calculations to investigate the adsorption properties of key CO2 reduction intermediates (CO2, H2, cis-COOH, trans-COOH, HCOO, CO, HCO, and COH) on Ni8, Ga8, Ni5Ga3, (ZrO2)16, and Ni5Ga3/(ZrO2)16. We found that Ni containing clusters tended to assume wetting configurations on the (ZrO2)16 cluster, while the presence of Ga atoms weakens the adsorption energies on the oxide surface. We also observed that CO2 was better activated on the metal–oxide interfaces and on the oxide surface, where it was able to form CO3-like structures. Meanwhile, H2 activation was only observed on Ni sites, which indicates the importance of distinct adsorption sites that can favor different CO2 reduction steps. Moreover, the formation of the metal–oxide interface showed to be beneficial for the adsorption of COOH isomers and unfavorable for the adsorption of HCOO.

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.

Solution combustion synthesis of Ni/La2O3 for dry reforming of methane: tuning the basicity via alkali and alkaline earth metal oxide promoters

The production of syngas via dry reforming of methane (DRM) has drawn tremendous research interest, ascribed to its remarkable economic and environmental impacts. Herein, we report the synthesis of K, Na, Cs, Li, and Mg-promoted Ni/La₂O₃ using solution combustion synthesis (SCS). The properties of the catalysts were determined by N₂ physisorption experiments, scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), X-ray photoelectron spectrometry (XPS), and H₂-TPR (temperature programmed reduction). In addition, their catalytic performance towards DRM was evaluated at 700 °C. The results demonstrated that all catalysts exhibited porous structures with high specific surface area, in particular, Mg-promoted Ni/La₂O₃ (Mg–Ni–La₂O₃) which depicted the highest surface area and highest pore volume (54.2 m² g⁻¹, 0.36 cm³ g⁻¹). Furthermore, Mg–Ni–La₂O₃ exhibited outstanding catalytic performance in terms of activity and chemical stability compared to its counterparts. For instance, at a gas hourly space velocity (GHSV) of 30 000 mL g⁻¹ h⁻¹, it afforded 83.2% methane conversion and 90.8% CO₂ conversion at 700 °C with no detectable carbon deposition over an operating period of 100 h. The superb DRM catalytic performance of Mg–Ni–La₂O₃ was attributed to the high specific surface area/porosity, strong metal-support interaction (MSI), and enhanced basicity, in particular the strong basic sites compared to other promoted catalysts. These factors remarkably enhance the catalytic performance and foster resistance to coke deposition.

Alkali and alkaline earth metal oxides-promoted Ni/La₂O₃ catalysts synthesized by solution combustion synthesis revealed enhanced catalytic performance towards dry reforming of methane.

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.

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.

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.

Catalytic Performance of Lanthanum Promoted Ni/ZrO2 for Carbon Dioxide Reforming of Methane

Nickel catalysts supported on zirconium oxide and modified by various amounts of lanthanum with 10, 15, and 20 wt.% were synthesized for CO2 reforming of methane. The effect of La2O3 as a promoter on the stability of the catalyst, the amount of carbon formed, and the ratio of H2 to CO were investigated. In this study, we observed that promoting the catalyst with La2O3 enhanced catalyst activities. The conversions of the feed, i.e., methane and carbon dioxide, were in the order 10La2O3 > 15La2O3 > 20La2O3 > 0La2O3, with the highest conversions being about 60% and 70% for both CH4 and CO2 respectively. Brunauer–Emmett–Teller (BET) analysis showed that the surface area of the catalysts decreased slightly with increasing La2O3 doping. We observed that 10% La2O3 doping had the highest specific surface area (21.6 m2/g) and the least for the un-promoted sample. The higher surface areas of the promoted samples relative to the reference catalyst is an indication of the concentration of the metals at the mouths of the pores of the support. XRD analysis identified the different phases available, which ranged from NiO species to the monoclinic and tetragonal phases of ZrO2. Temperature programmed reduction (TPR) analysis showed that the addition of La2O3 lowered the activation temperature needed for the promoted catalysts. The structural changes in the morphology of the fresh catalyst were revealed by microscopic analysis. The elemental compositions of the catalyst, synthesized through energy dispersive X-ray analysis, were virtually the same as the calculated amount used for the synthesis. The thermogravimetric analysis (TGA) of spent catalysts showed that the La2O3 loading of 10 wt.% contributed to the gasification of carbon deposits and hence gave about 1% weight-loss after a reaction time of 7.5 h at 700 °C.

Dry reforming of methane by stable Ni-Mo nanocatalysts on single-crystalline MgO

Large-scale carbon fixation requires high-volume chemicals production from carbon dioxide. Dry reforming of methane could provide an economically feasible route if coke- and sintering-resistant catalysts were developed. Here, we report a molybdenum-doped nickel nanocatalyst that is stabilized at the edges of a single-crystalline magnesium oxide (MgO) support and show quantitative production of synthesis gas from dry reforming of methane. The catalyst runs more than 850 hours of continuous operation under 60 liters per unit mass of catalyst per hour reactive gas flow with no detectable coking. Synchrotron studies also show no sintering and reveal that during activation, 2.9 nanometers as synthesized crystallites move to combine into stable 17-nanometer grains at the edges of MgO crystals above the Tammann temperature. Our findings enable an industrially and economically viable path for carbon reclamation, and the "Nanocatalysts On Single Crystal Edges" technique could lead to stable catalyst designs for many challenging reactions.

Highly Carbon-Resistant Y Doped NiO–ZrOm Catalysts for Dry Reforming of Methane

Yttrium-doped NiO–ZrOm catalyst was found to be novel for carbon resistance in the CO2 reforming of methane. Yttrium-free and -doped NiO–ZrOm catalysts were prepared by a one-step urea hydrolysis method and characterized by Brunauer-Emmett-Teller (BET), TPR-H2, CO2-TPD, XRD, TEM and XPS. Yttrium-doped NiO–ZrOm catalyst resulted in higher interaction between Ni and ZrOm, higher distribution of weak and medium basic sites, and smaller Ni crystallite size, as compared to the Y-free NiO–ZrOm catalyst after reaction. The DRM catalytic tests were conducted at 700 °C for 8 h, leading to a significant decrease of activity and selectivity for the yttrium-doped NiO–ZrOm catalyst. The carbon deposition after the DRM reaction on yttrium-doped NiO–ZrOm catalyst was lower than on yttrium-free NiO–ZrOm catalyst, which indicated that yttrium could promote the inhibition of carbon deposition during the DRM process.

Fe-rich biomass derived char for microwave-assisted methane reforming with carbon dioxide

Microwave-assisted methane reforming with carbon dioxide was dealt with in this work, using a Fe-rich biomass-derived char by one-step preparation. The main factors on the reforming reaction and stability of this catalyst were evaluated, together with a series of characterization on the produced gas and the used char. The char obtained from biomass pyrolysis with Fe₂O₃ addition of 10% exhibited the best performance on dry reforming reaction. A target CH₄ conversion of 95% over this char was realized at 800 °C. Moreover, H₂/CO ratio achieved with this char was prone to approach the stoichiometric value. Compared to CO₂ conversion, CH₄ conversion was more promoted with the increase of CO₂/CH₄ ratio. The variation of CO₂/CH₄ ratio also leaded to a noticeable changes on H₂/CO ratio. More importantly, the selected char presented a satisfied stability, evidenced by the total decrease of 4.8% for CH₄ conversion and 3.1% for CO₂ conversion in the test of 160 min. This was contributed to a depressed in-situ carbon consumption and a moderate deterioration of porous structure. Gaseous products obtained with the appropriate char in a long run had a syngas content of 88.79% and H₂/CO ratio of 0.92 on average.

Dry Reforming of Methane on Carriers and Oxide Catalysts to Synthesis-Gas

The catalytic activity of carriers: θ‒Al2O3, γ‒Al2O3, 5A, 4A, 3A and 13X and the oxides of metals of variable valency ‒ NiO, La2O3, CuO, MoO3, MgO, V2O5, WO3, CoO, Cr2O3, ZnO, ZrO2, CeO2, Fe2O3, supported on the effective carrier γ‒Al2O3 by the method of capillary impregnation of the support with solutions of nitric salts of metals were investigated in the process of carbon dioxide conversion of methane (DRM). The optimal technological regimes for the process were: the reaction temperature -800 °C, the space velocity of the initial reactants ‒ 1500 h-1 with a methane to carbon dioxide ratio equal to 1. It was found that among the studied catalysts the highest activity is shown by the NiO/γ‒Al2O3 catalyst, where the yields of hydrogen and carbon monoxide reaches 45.4 and 42.4% by volume, respectively, when methane conversion is 89%. The XRF method showed that the content of alumina and nickel oxide after the reaction remained unchanged at 96.7 and 3.0%, respectively. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), small angle X-ray scattering (XRS) determined that nickel-containing NiO/γ‒Al2O3 catalyst form nickel nanoparticles (6.4‒10 and 50‒150 nm) and a uniform their distribution on the surface of the carrier takes place. These physical chemical characteristics have a positive effect on the activity of NiO/γ‒Al2O3 catalyst in the process of carbon dioxide conversion of methane to synthesis gas.

Robust mesoporous bimetallic yolk–shell catalysts for chemical CO2 upgrading via dry reforming of methane

A new generation highly efficient and stable mesoporous ZnO/Ni@silica yolk–shell catalyst is designed for chemical CO₂ recycling, to solve the coking and sintering issues of traditional catalysts.