Dry reforming of methane for syngas production: A review and assessment of catalyst development and efficacy

Understanding Coke Deposition Vis-à-Vis DRM Activity over Magnesia-Alumina Supported Ni-Fe, Ni-Co, Ni-Ce, and Ni-Sr Catalysts

The catalytic conversion of CH4 and CO2 into H2-rich syngas is known as the dry reforming of methane (DRM). The dissociation of CH4 over active sites, coupled with the oxidation or polymerization of CH4-x (x = 1-4), plays a crucial role in determining in determining the DRM product yield and coke deposition. Herein, a series of bimetallic-supported catalysts are prepared by the dispersion of Ni-M (M = Ce, Co, Fe, and Sr) over 60 wt% MgO-40 wt% Al2O3 (60Mg40Al) support. Catalysts are tested for DRM and characterized with XRD, surface area and porosity, temperature-programmed reduction/desorption, UV-VIS-Raman spectroscopy, and thermogravimetry. 2.5Ni2.5Sr/60Mg40Al and 2.5Ni2.5Fe/60Mg40Al, and 2.5Ni2.5Ce/60Mg40Al and 2.5Ni2.5Co/60Mg40Al have similar CO2 interaction profiles. The 2.5Ni2.5Sr/60Mg40Al catalyst nurtures inert-type coke, whereas 2.5Ni2.5Fe/60Mg40Al accelerates the deposition of huge coke, which results in catalytic inferiority. The higher activity over 2.5Ni2.5Ce/60Mg40Al is due to the instant lattice oxygen-endowing capacity for oxidizing coke. Retaining a high DRM activity (54% H2-yield) up to 24 h even against a huge coke deposition (weight loss 46%) over 2.5Ni2.5Co/60Mg40Al is due to the timely diffusion of coke far from the active sites or the mounting of active sites over the carbon nanotube.

Development of Photothermal Catalyst from Biomass Ash (Bagasse) for Hydrogen Production via Dry Reforming of Methane (DRM): An Experimental Study

Conventional hydrogen production, as an alternative energy resource, has relied on fossil fuels to produce hydrogen, releasing CO₂ into the atmosphere. Hydrogen production via the dry forming of methane (DRM) process is a lucrative solution to utilize greenhouse gases, such as carbon dioxide and methane, by using them as raw materials in the DRM process. However, there are a few DRM processing issues, with one being the need to operate at a high temperature to gain high conversion of hydrogen, which is energy intensive. In this study, bagasse ash, which contains a high percentage of silicon dioxide, was designed and modified for catalytic support. Modification of silicon dioxide from bagasse ash was utilized as a waste material, and the performance of bagasse ash-derived catalysts interacting with light irradiation and reducing the amount of energy used in the DRM process was explored. The results showed that the performance of 3%Ni/SiO₂ bagasse ash WI was higher than that of 3%Ni/SiO₂ commercial SiO₂ in terms of the hydrogen product yield, with hydrogen generation initiated in the reaction at 300 °C. Using the same synthesis method, the current results suggested that bagasse ash-derived catalysts had better performance than commercial SiO₂-derived catalysts when exposed to an Hg-Xe lamp. This indicated that silicon dioxide from bagasse ash as a catalyst support could help improve the hydrogen yield while lowering the temperature in the DRM reaction, resulting in less energy consumption in hydrogen production.

Profitable Fischer Tropsch realization via CO2-CH4 reforming; an overview of nickel-promoter-support interactions

Environmental pollution, climate change, and fossil fuel extinction have aroused serious global interest in the search for alternative energy sources. The dry reforming of methane (DRM) could be a good technique to harness syngas, a starting material for the FT energy process from greenhouse gases. Noble metal DRM catalysts are effective for the syngas generation but costly. Therefore, they inevitably, must be replaced by their Ni-based contemporaries for economic reasons. However, coking remains a strong challenge that impedes the industrialization of the FT process. This article explains the secondary reactions that lead to the production of detrimental graphitic coke deposition on the surface of active nickel catalyst. The influence of nickel particle size, impact of extra surface oxygen species, interaction of Ni catalysts with metal oxide supports/promoters, and larger fraction of exposed nickel active sites were addressed in this review. Size of active metal determines the conversion, surface area, metal dispersion, surface reactions, interior diffusion effects, activity, and yield. The influence of oxygen vacancy and coke deposition on highly reported metal oxide supports/promoters (Al₂O₃, MgO and La₂O₃) was postulated after studying CIFs (crystallographic information files) obtained from the Crystallography open database (COD) on VESTA software. Thus, overcoming excessive coking by La₂O₃ promotion is strongly advised in light of the orientation of the crystal lattice characteristics and the metal-support interaction can be used to enhance activity and stability in hydrogen reforming systems.

Supercritical fluid-assisted modification combined with the resynthesis of SmCoO3 as an effective tool to enhance the long-term performance of SmCoO3-derived catalysts for the dry reforming of methane to syngas

The dry reforming of methane to syngas (DRM) is of increasing significance concerning, first, the production of raw materials for commercial organic/petrochemical syntheses and for hydrogen energetic, and, second, the utilization of two most harmful greenhouse gases. Herein, new SmCoO₃-based DRM catalysts derived from heterometallic precursors and operated without preliminary reduction are reported. For the first time, the effect of supercritical fluids-assisted modification of the SmCoO₃-derived catalysts combined with the re-oxidation of spent catalysts to SmCoO₃ onto its long-term performance was studied. In particular, the modification of heterometallic precursors by supercritical antisolvent precipitation (SAS) considerably decreases coke formation upon the exploitation of the derived SmCoO₃ sample. Moreover, the re-oxidation of the corresponding spent catalysts followed by pre-heating under N₂ affords catalysts that stably provide syngas yields of 88-95% for at least 41 h at 900 °C. The achieved yields are among the highest ones currently reported for DRM catalysts derived from both LnMO₃ perovskites and related oxides. The origins of such good performance are discussed. Given the simplicity and availability of all the applied methods and chemicals, this result opens prospects for exploiting SAS in the design of efficient DRM catalysts.

Evaluation of promoted Ni-based nanocatalysts in wall-coated microchannel reactor on the dry reforming of methane and effect of ultrasound waves on physiochemical properties of synthesized nanocatalysts

The deactivation of nickel catalysts in the dry reforming of methane (DRM) process has been one of the issues of interest to researchers. In this research, the effect of active phase and support promoter uses and synthesis method on synthesized Ni–Co/Al2O3–MgO nanocatalysts efficiency in wall coated microreactor on dry reforming of methane process studied. To determine the characteristics of the synthesized samples, XRD, BET, FESEM, and Ft-IR analyses have been performed. Analyses show that the use of ultrasound waves in the synthesis of catalysts improves the catalyst surface morphology so that about 82% of the particles of the synthesized sample are smaller than 100 nm and , increases the specific surface area to an average of 10%, and makes its structure smaller. Also, the total pore volume on the surface of the samples also shows a 10% increase. The use of promoters increases the catalyst activity and makes it more stable up to 18 h on stream. The use of a wall-coated microreactor improves heat transfer, easier access of reactants to active sites, no pressure drop, and higher activity than a conventional U-type fixed bed reactor. Nanocatalysts with Ni/Co = 5 and Al/Mg = 5 has shown the highest and most stable activity throughout the temperature range in the DRM process.

Dry Reforming of Methane on Ni/Nanorod-CeO2 Catalysts Prepared by One-Pot Hydrothermal Synthesis: The Effect of Ni Content on Structure, Activity, and Stability

The nanorod morphology of the CeO2 support has been recognized as more beneficial than other morphologies for catalytic activity in the dry reforming of methane. Ni/nanorod-CeO2 catalysts with different Ni contents were prepared by one-pot hydrothermal synthesis. Samples were characterized by X-ray diffraction (XRD), H2-temperature-programmed reduction (H2-TPR), H2-temperature-programmed desorption (H2-TPD), field emission scanning electron microscopy/energy dispersive spectroscopy (FE-SEM/EDS), Brunauer–Emmet–Teller (BET) and Barrett–Joyner–Halenda (BHJ) analysis. The effect of Ni content on the size and the intrinsic strain of ceria was analyzed by the Size–Strain plot and Williamson–Hall plot of XRD data. The average Ni particle size and Ni dispersion were determined by H2-TPD. XRD and H2-TPR analysis revealed a strong Ni–support interaction that limited nickel sintering. The activity for the dry reforming of methane was tested with the stoichiometric mixture CO2:CH4:N2:He = 20:20:20:140, gas hourly space velocity (GHSV) = 300 L g−1 h−1, and temperatures in the range of 545–800 °C. The turnover frequency (TOF) value increased linearly with the average Ni particle size in the range of 5.5–33 nm, suggesting the structure sensitivity of the reaction. Samples with Ni loading of 4–12 wt.% showed high H2/CO selectivity and stability over time on stream, whereas the sample with a Ni loading of 2 wt.% was less selective and underwent rapid deactivation. Only a small amount of nanotubular carbon was observed by FE-SEM after the time-on-stream experiment. Deactivation of the low-Ni-content sample is ascribed to the easier oxidation of the small Ni particles.

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.

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.