High-Performance Binary Mo–Ni Catalysts for Efficient Carbon Removal during Carbon Dioxide Reforming of Methane

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.

Simultaneous production of syngas and carbon nanotubes from CO2/CH4 mixture over high-performance NiMo/MgO catalyst

Direct conversion of biogas via the integrative process of dry reforming of methane (DRM) and catalytic methane decomposition (CDM) has received a great attention as a promising green catalytic process for simultaneous production of syngas and carbon nanotubes (CNTs). In this work, the effects of reaction temperature of 700-1100 °C and CH4/CO2 ratio of biogas were investigated over NiMo/MgO catalyst in a fixed bed reactor under industrial feed condition of pure biogas. The reaction at 700 °C showed a rapid catalyst deactivation within 3 h due to the formation of amorphous carbon on catalyst surface. At higher temperature of 800-900 °C, the catalyst can perform the excellent performance for producing syngas and carbon nanotubes. Interestingly, the smallest diameter and the highest graphitization of CNTs was obtained at high temperature of 1000 °C, while elevating temperature to 1100 °C leads to agglomeration of Ni particles, resulting in a larger size of CNTs. The reaction temperature exhibits optimum at 800 °C, providing the highest CNTs yield with high graphitization, high syngas purity up to 90.04% with H2/CO ratio of 1.1, and high biogas conversion (XCH4 = 86.44%, XCO2 = 95.62%) with stable performance over 3 h. The typical composition biogas (CH4/CO2 = 1.5) is favorable for the integration process, while the CO2 rich biogas caused a larger grain size of catalyst and a formation of molybdenum oxide nanorods (MoO3). The long-term stability of NiMo/MgO catalyst at 800 °C showed a stable trend (> 20 h). The experimental findings confirm that NiMo/MgO can perform the excellent activity and high stability at the optimum condition, allowing the process to be more promising for practical applications.

Facilitating the dry reforming of methane with interfacial synergistic catalysis in an Ir@CeO2-x catalyst

The dry reforming of methane provides an attractive route to convert greenhouse gases (CH4 and CO2) into valuable syngas, so as to resolve the carbon cycle and environmental issues. However, the development of high-performance catalysts remains a huge challenge. Herein, we report a 0.6% Ir/CeO2-x catalyst with a metal-support interface structure which exhibits high CH4 (~72%) and CO2 (~82%) conversion and a CH4 reaction rate of ~973 μmolCH4 gcat-1 s-1 which is stable over 100 h at 700 °C. The performance of the catalyst is close to the state-of-the-art in this area of research. A combination of in situ spectroscopic characterization and theoretical calculations highlight the importance of the interfacial structure as an intrinsic active center to facilitate the CH4 dissociation (the rate-determining step) and the CH2* oxidation to CH2O* without coke formation, which accounts for the long-term stability. The catalyst in this work has a potential application prospect in the field of high-value utilization of carbon resources.

Highly Efficient and Stable Methane Dry Reforming Enabled by a Single-Site Cationic Ni Catalyst

Zeolite-supported nickel (Ni) catalysts have been extensively studied for the dry reforming of methane (DRM). It is generally believed that prior to or during the reaction, Ni is reduced to a metallic state to act as the catalytic site. Here, we employed a ligand-protected synthesis method to achieve a high degree of Ni incorporation into the framework of the MFI zeolite. The incorporated Ni species retained their cationic nature during the DRM reaction carried out at 600 °C, exhibiting higher apparent catalytic activity and significantly greater catalytic stability in comparison to supported metallic Ni particles at the same loading. From theoretical and experimental evidence, we conclude that the incorporation of Ni into the zeolite framework leads to the formation of metal-oxygen (Niδ+-O(2-ξ)-) pairs, which serve as catalytic active sites, promoting the dissociation of C-H bonds in CH4 through a mechanism distinct from that of metallic Ni. The conversion of CH4 on cationic Ni single sites follows the CHx oxidation pathway, which is characterized by the rapid transformation of partial cracking intermediates CHx*, effectively inhibiting coke formation. The presence of the CHx oxidation pathway was experimentally validated by identifying the reaction intermediates. These new mechanistic insights elucidate the exceptional performance of the developed Ni-MFI catalyst and offer guidance for designing more efficient and stable Ni-based DRM catalysts.

Light-Reinforced Key Intermediate for Anticoking To Boost Highly Durable Methane Dry Reforming over Single Atom Ni Active Sites on CeO2

Dry reforming of methane (DRM) has been investigated for more than a century; the paramount stumbling block in its industrial application is the inevitable sintering of catalysts and excessive carbon emissions at high temperatures. However, the low-temperature DRM process still suffered from poor reactivity and severe catalyst deactivation from coking. Herein, we proposed a concept that highly durable DRM could be achieved at low temperatures via fabricating the active site integration with light irradiation. The active sites with Ni-O coordination (NiSA/CeO2) and Ni-Ni coordination (NiNP/CeO2) on CeO2, respectively, were successfully constructed to obtain two targeted reaction paths that produced the key intermediate (CH3O*) for anticoking during DRM. In particular, the operando diffuse reflectance infrared Fourier transform spectroscopy coupling with steady-state isotopic transient kinetic analysis (operando DRIFTS-SSITKA) was utilized and successfully tracked the anticoking paths during the DRM process. It was found that the path from CH3* to CH3O* over NiSA/CeO2 was the key path for anticoking. Furthermore, the targeted reaction path from CH3* to CH3O* was reinforced by light irradiation during the DRM process. Hence, the NiSA/CeO2 catalyst exhibits excellent stability with negligible carbon deposition for 230 h under thermo-photo catalytic DRM at a low temperature of 472 °C, while NiNP/CeO2 shows apparent coke deposition behavior after 0.5 h in solely thermal-driven DRM. The findings are vital as they provide critical insights into the simultaneous achievement of low-temperature and anticoking DRM process through distinguishing and directionally regulating the key intermediate species.

Synergistic promotions between CO2 capture and in-situ conversion on Ni-CaO composite catalyst

The integrated CO₂ capture and conversion (iCCC) technology has been booming as a promising cost-effective approach for Carbon Neutrality. However, the lack of the long-sought molecular consensus about the synergistic effect between the adsorption and in-situ catalytic reaction hinders its development. Herein, we illustrate the synergistic promotions between CO₂ capture and in-situ conversion through constructing the consecutive high-temperature Calcium-looping and dry reforming of methane processes. With systematic experimental measurements and density functional theory calculations, we reveal that the pathways of the reduction of carbonate and the dehydrogenation of CH₄ can be interactively facilitated by the participation of the intermediates produced in each process on the supported Ni-CaO composite catalyst. Specifically, the adsorptive/catalytic interface, which is controlled by balancing the loading density and size of Ni nanoparticles on porous CaO, plays an essential role in the ultra-high CO₂ and CH₄ conversions of 96.5% and 96.0% at 650 °C, respectively.

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.

Identification of Highly Selective Surface Pathways for Methane Dry Reforming Using Mechanochemical Synthesis of Pd-CeO2

The methane dry reforming (DRM) reaction mechanism was explored via mechanochemically prepared Pd/CeO2 catalysts (PdAcCeO2M), which yield unique Pd-Ce interfaces, where PdAcCeO2M has a distinct reaction mechanism and higher reactivity for DRM relative to traditionally synthesized impregnated Pd/CeO2 (PdCeO2IW). In situ characterization and density functional theory calculations revealed that the enhanced chemistry of PdAcCeO2M can be attributed to the presence of a carbon-modified Pd0 and Ce4+/3+ surface arrangement, where distinct Pd-CO intermediate species and strong Pd-CeO2 interactions are activated and sustained exclusively under reaction conditions. This unique arrangement leads to highly selective and distinct surface reaction pathways that prefer the direct oxidation of CH x to CO, identified on PdAcCeO2M using isotope labeled diffuse reflectance infrared Fourier transform spectroscopy and highlighting linear Pd-CO species bound on metallic and C-modified Pd, leading to adsorbed HCOO [1595 cm-1] species as key DRM intermediates, stemming from associative CO2 reduction. The milled materials contrast strikingly with surface processes observed on IW samples (PdCeO2IW) where the competing reverse water gas shift reaction predominates.

Development of high-performance nickel-based catalysts for production of hydrogen and carbon nanotubes from biogas

Selecting a suitable catalyst for implementing the simultaneous production of hydrogen-rich syngas and multi-walled carbon nanotubes through the integration of dry reforming and methane decomposition reactions has recently gained great interests. In this study, a series of bimetallic (NiMo/MgO) and trimetallic (CoNiMo/MgO, FeNiMo/MgO, CoFeMo/MgO) catalysts was prepared and evaluated for a catalytic activity of CH₄ and CO₂ conversions of biogas in a fixed bed reactor at 800 °C and atmospheric pressure. Among the investigated catalysts, the bimetallic NiMo/MgO catalyst showed the outstanding catalytic performance with 86.4% CH₄ conversion and 95.6% CO₂ conversion as well as producing the highest syngas purity of 90.0% with H₂/CO ratio = 1.1. Moreover, the characterization of the synthesized solid products proved that the well-aligned structured morphology, high purity, and excellent textural properties of CNTs were obtained by using NiMo/MgO catalyst. On the other hand, using trimetallic catalysts which have the composition of Co and Fe leads to the severe deactivation. This could be attributed the catalyst oxidation with CO₂ in biogas, resulting in the transformation of metals into large metal oxides. The integrative process with NiMo/MgO catalyst is regarded as a promising pathway, which has a high potential for directly converting biogas into the high value-added products and providing a green approach for managing the enormous amounts of wastes.

Coking- and Sintering-Resistant Ni Nanocatalysts Confined by Active BN Edges for Methane Dry Reforming

Methane dry reforming (MDR) has attracted significant attention for effectively consuming greenhouse gases and producing valuable syngas. The development of coking- and sintering-resistant catalysts is still a challenge. Herein, highly active Ni nanocatalysts confined by the active edges of boron nitride have been originally developed, and the coking- and sintering-resistant MDR mechanism has also been unraveled. The active edges of boron nitride consisted of boundary BO_x species interact with Ni nanoparticles (NPs), which can contribute to the activation of both CH₄ and CO₂. The etching of BN is restrained under the buffer of boundary BO_x species. Operando spectra reveal that the formation and conversion of active bicarbonate species is accelerated by the boundary BO_x species. The complete decomposition of CH₄ is suppressed, and thus the coke formation is restricted. The functional groups of active BN edges are confirmed to stabilize the Ni NPs and facilitate the MDR reaction. This work provides a novel approach for the development of coking- and sintering-resistant catalysts for MDR.

Promoting dry reforming of methane catalysed by atomically-dispersed Ni over ceria-upgraded boron nitride

Dry reforming of methane (DRM) is a very promising protocol to mitigate the greenhouse gases by making use of CO 2 and CH 4 to produce valuable syngas. Ni-Based catalysts exhibit high activity and low cost for DRM, but suffer from inferior stability because of serious carbon deposition. Herein, we proposed atomically dispersed Ni supported by ceria-upgraded boron nitride whose specific activity exceeds that of boron nitride supported Ni by 3 times. The results of temperature programmed surface reaction show ceria enhanced the adsorption of CO 2 and its surface-active oxygen species would contribute to the activation of CH 4 . Moreover, Ni exhibited a strong metal-support interaction which suppressed the metal sintering during DRM reaction while the incorporation of BN could suppress carbon deposition. The incorporation of active metal oxides into inert support provides a route to adjust the interaction between metal and support and achieve the synergistic promoting in catalytic performance.