Effect of Cerium Promoters on an MCM-41-Supported Nickel Catalyst in Dry Reforming of Methane

Iron-promoted zirconia-alumina supported Ni catalyst for highly efficient and cost-effective hydrogen production via dry reforming of methane

Developing cost-effective and high-performance catalyst systems for dry reforming of methane (DRM) is crucial for producing hydrogen (H2) sustainably. Herein, we investigate using iron (Fe) as a promoter and major alumina support in Ni-based catalysts to improve their DRM performance. The addition of iron as a promotor was found to add reducible iron species along with reducible NiO species, enhance the basicity and induce the deposition of oxidizable carbon. By incorporating 1 wt.% Fe into a 5Ni/10ZrAl catalyst, a higher CO2 interaction and formation of reducible "NiO-species having strong interaction with support" was observed, which led to an ∼80% H2 yield in 420 min of Time on Stream (TOS). Further increasing the Fe content to 2wt% led to the formation of additional reducible iron oxide species and a noticeable rise in H2 yield up to 84%. Despite the severe weight loss on Fe-promoted catalysts, high H2 yield was maintained due to the proper balance between the rate of CH4 decomposition and the rate of carbon deposit diffusion. Finally, incorporating 3 wt.% Fe into the 5Ni/10ZrAl catalyst resulted in the highest CO2 interaction, wide presence of reducible NiO-species, minimum graphitic deposit and an 87% H2 yield. Our findings suggest that iron-promoted zirconia-alumina-supported Ni catalysts can be a cheap and excellent catalytic system for H2 production via DRM.

Ni-Sr/TiZr for H2 from methane via POM: Sr loading & optimization

Achieving remarkable H2 yield with significantly high H2/CO over Ni-based catalysts through partial oxidation of methane (POM) is a realistic approach to depleting the concentration of CH4 and using H2 and CO as synthetic feedstock. This study examined Ni catalysts on titania-zirconia for methane conversion via POM at 600 °C and atmospheric pressure. The addition of strontium to the catalyst was explored to improve its performance. Catalysts were characterized by X-ray diffraction, Raman-infrared-UV-vis spectroscopy, and Temperature-programmed reduction-desorption techniques (TPR, TPD). 2.5 wt% Sr addition induced the formation of the highest concentration of extreme basic sites. Interestingly, over the unpromoted catalyst, active sites are majorly generated by hardly reducible NiO species whereas upon 2.5 wt% promoted Sr promotional addition, most of active sites are derived by easily reducible NiO species. 45% CH4 conversion and 47% H2 yield with H2/CO = 3.5 were achieved over 2.5 wt% Sr promoted 5Ni/30TiO2 + ZrO2 catalyst. These results provide insight into the role of basic sites in enhancing activity through switching indirect pathways over direct pathways for POM. Further process optimization was carried out in the range of 10 000-22 000 SV, 0.35-0.75 O2/CH4, and 600-800 °C reaction temperature over 5Ni2.5Sr/30TiO2 + ZrO2 by using central composite design under response surface methodology. The optimum activity as high as ∼88% CH4 conversion, 86-87% yield of H2, and 2.92H2/CO were predicted and experimentally validated at 800 °C reaction temperature, 0.35O2/CH4 ratio, and 10 000 space velocity.

Impact of Sr Addition on Zirconia-Alumina-Supported Ni Catalyst for COx-Free CH4 Production via CO2 Methanation

Zirconia-alumina-supported Ni (5Ni/10ZrO2+Al2O3) and Sr-promoted 5Ni/10ZrO2+Al2O3 are prepared, tested for carbon dioxide (CO2) methanation at 400 °C, and characterized by X-ray diffraction, X-ray photoelectron spectroscopy, surface area and porosity, infrared spectroscopy, and temperature-programmed reduction/desorption techniques. The CO2 methanation is found to depend on the dispersion of Nickel (Ni) sites as well as the extent of stabilization of CO2-interacted species. The Ni active sites are mainly derived from the reduction of 'moderately interacted NiO species'. The dispersion of Ni over 1 wt % Sr-promoted 5Ni/10ZrO2+Al2O3 is 1.38 times that of the unpromoted catalyst, and it attains 72.5% CO2 conversion (against 65% over the unpromoted catalyst). However, increasing strontium (Sr) loading to 2 wt % does not affect the Ni dispersion much, but the concentration of strong basic sites is increased, which achieves 80.6% CO2 conversion. The 5Ni4Sr/10ZrO2+Al2O3 catalyst has the highest density of strong basic sites and the highest concentration of active sites with maximum Ni dispersion. This catalyst displays exceptional performance and achieves approximately 80% CO2 conversion and 70% methane (CH4) yield for up to 25 h on steam. The unique acidic-basic profiles composed of strong basic and moderate acid sites facilitate the sequential hydrogenation of formate species in the COx-free CH4 route.

Alumina-Magnesia-Supported Ni for Hydrogen Production via the Dry Reforming of Methane: A Cost-Effective Catalyst System

5Ni/MgO and 5Ni/γAl2O3 are pronounced in the line of cheap catalyst systems for the dry reforming of methane. However, the lower reducibility of 5Ni/MgO and the significant coke deposition over 5Ni/γAl2O3 limit their applicability as potential DRM catalysts. The mixing capacity of MgO and Al2O3 may overcome these limitations without increasing the catalyst cost. Herein, a 5Ni/xMg(100 - x)Al (x = 0, 20, 30, 60, 70, and 100 wt. %) catalyst system is prepared, investigated, and characterized with X-ray diffraction, surface area and porosity measurements, H2-temperature programmed reduction, UV-Vis-IR spectroscopy, Raman spectroscopy, thermogravimetry, and transmission electron microscopy. Upon the addition of 20 wt. % MgO into the Al2O3 support, 5Ni/20Mg80Al is expanded and carries both stable Ni sites (derived through the reduction of NiAl2O4) and a variety of CO2-interacting species. CH4 decomposition at Ni sites and the potential oxidation of carbon deposits by CO2-interacting species over 5Ni/20Mg80Al results in a higher 61% H2-yield (against ~55% H2-yield over 5Ni/γAl2O3) with an excellent carbon-resistant property. In the major magnesia support system, the 5Ni/60Mg40Al catalyst carries stable Ni sites derived from MgNiO2 and "strongly interacted NiO-species". The H2-yield over the 5Ni/60Mg40Al catalyst moves to 71%, even against a high coke deposition, indicating fine tuning between the carbon formation and diffusion rates. Ni dispersed over magnesia-alumina with weight ratios of 7/3 and 3/7 exhibit good resistance to coke. Weight ratios of 2/8 and 7/3 contain an adequate amount of reducible and CO2-interactive species responsible for producing over 60% of H2-yield. Weight ratio 6/4 has a proper coke diffusion mechanism in addition to achieving a maximum of 71% H2-yield.

Carbon Dioxide Valorization into Methane Using Samarium Oxide-Supported Monometallic and Bimetallic Catalysts

Samarium oxide (Sm2O3) is a versatile surface for CO2 and H2 interaction and conversion. Samarium oxide-supported Ni, samarium oxide-supported Co-Ni, and samarium oxide-supported Ru-Ni catalysts were tested for CO2 methanation and were characterized by X-ray diffraction, nitrogen physisorption, infrared spectroscopy, H2-temperature programmed reduction, and X-ray photoelectron spectroscopy. Limited H2 dissociation and widely available surface carbonate and formate species over 20 wt.% Ni, dispersed over Sm2O3, resulted in ~98% CH4 selectivity. The low selectivity for CO could be due to the reforming reaction between CH4 (methanation product) and CO2. Co-impregnation of cobalt with nickel over Sm2O3 had high surface adsorbed oxygen and higher CO selectivity. On the other hand, co-impregnation of ruthenium and nickel over Sm2O3 led to more than one catalytic active site, carbonate species, lack of formate species, and 94% CH4 selectivity. It indicated the following route of CH4 synthesis over Ru-Ni/Sm2O3; carbonate → unstable formate → CO → CH4.

Dry Reforming of Methane with Mesoporous Ni/ZrO2 Catalyst

Dry reforming of methane has exhibited significant environmental benefits as it utilizes two major greenhouse gases (CO2 and CH4) to produce synthesis gas, a major building block for hydrocarbons. This process has gained industrial attention as catalyst deactivation due to coke deposition being a major hindrance. The present study focuses on the dry reforming of methane over Ni-supported mesoporous zirconia support. Ni metal was loaded over in-house synthesized mesoporous zirconia within the 0–15 wt% range using the wet impregnation method. The physicochemical properties of the synthesized catalysts were studied using various characterization techniques, namely, XRD, SEM, FTIR, TGA, and N2 adsorption-desorption techniques. The activity of all the catalysts was evaluated at 750°C and gas hourly space velocity (GHSV) of 72000 ml/h/gcat for 9 hours (540 min). The deactivation factor indicating a loss in conversion with time is reported for each catalyst. 10 wt% Ni/ZrO2 showed the highest feed conversion of about 68.8% for methane and 70.2% for carbon dioxide and the highest stability (15.1% deactivation factor and 21% weight loss) for dry reforming of methane to synthesis gas.

Barium-Promoted Yttria-Zirconia-Supported Ni Catalyst for Hydrogen Production via the Dry Reforming of Methane: Role of Barium in the Phase Stabilization of Cubic ZrO2

Developing cost-effective nonprecious active metal-based catalysts for syngas (H₂/CO) production via the dry reforming of methane (DRM) for industrial applications has remained a challenge. Herein, we utilized a facile and scalable mechanochemical method to develop Ba-promoted (1-5 wt %) zirconia and yttria-zirconia-supported Ni-based DRM catalysts. BET surface area and porosity measurements, infrared, ultraviolet-visible, and Raman spectroscopy, transmission electron microscopy, and temperature-programmed cyclic (reduction-oxidation-reduction) experiments were performed to characterize and elucidate the catalytic performance of the synthesized materials. Among different catalysts tested, the inferior catalytic performance of 5Ni/Zr was attributed to the unstable monoclinic ZrO₂ support and weakly interacting NiO species whereas the 5Ni/YZr system performed better because of the stable cubic ZrO₂ phase and stronger metal-support interaction. It is established that the addition of Ba to the catalysts improves the oxygen-endowing capacity and stabilization of the cubic ZrO₂ and BaZrO₃ phases. Among the Ba-promoted catalysts, owing to the optimal active metal particle size and excess ionic CO₃ ^2- species, the 5Ni4Ba/YZr catalyst demonstrated a high, stable H₂ yield (i.e., 79% with a 0.94 H₂/CO ratio) for up to 7 h of time on stream. The 5Ni4Ba/YZr catalyst had the highest H₂ formation rate, 1.14 mol g^-1 h^-1 and lowest apparent activation energy, 20.07 kJ/mol, among all zirconia-supported Ni catalyst systems.

The Effect of Calcination Temperature on Various Sources of ZrO2 Supported Ni Catalyst for Dry Reforming of Methane

Dry reforming of methane (DRM) over an Ni-based catalyst is an innovative research area due to the growing environmental awareness about mitigating global warming gases (CH4 and CO2) and creating a greener route of synthesis. Herein, 5% Ni supported on ZrO2 obtained from various sources was prepared by the impregnation method. The catalysts were calcined at 600, 700, and 800 °C. Furthermore, Ni-RC stabilized with MgO, SiO2, TiO2, and Y2O3 were tested. Characterization techniques employed comprise the N2 physisorption, infrared spectroscopy, Raman, thermogravimetric analysis, XRD, and TEM. The results of the present study indicated that the ZrO2 support source had a profound effect on the overall performance of the process. The best catalyst Ni-RC gave an average conversion of CH4 and CO2 of 61.5% and 63.6% and the least deactivation of 10.3%. The calcination pretreatment differently influenced the catalyst performance. When the average methane conversion was higher than 40%, increasing the calcination temperature decreased the activity. While for the low activity catalysts with an average methane conversion of less than 40% the impact of the calcination temperature did not constantly decrease with the temperature rise. The stabilization of Ni-RC denoted the preference Y2O3 stabilized catalyst with average values of CH4 and CO2 conversion of about 67% and 72%, respectively. The thorough study and fine correlation will be advantageous for technologically suitable Ni-15Y-RC catalysts for DRM.