A Review on the Different Aspects and Challenges of the Dry Reforming of Methane (DRM) Reaction

The dry reforming of methane (DRM) reaction is among the most popular catalytic reactions for the production of syngas (H2/CO) with a H2:CO ratio favorable for the Fischer-Tropsch reaction; this makes the DRM reaction important from an industrial perspective, as unlimited possibilities for production of valuable products are presented by the FT process. At the same time, simultaneously tackling two major contributors to the greenhouse effect (CH4 and CO2) is an additional contribution of the DRM reaction. The main players in the DRM arena-Ni-supported catalysts-suffer from both coking and sintering, while the activation of the two reactants (CO2 and CH4) through different approaches merits further exploration, opening new pathways for innovation. In this review, different families of materials are explored and discussed, ranging from metal-supported catalysts, to layered materials, to organic frameworks. DRM catalyst design criteria-such as support basicity and surface area, bimetallic active sites and promoters, and metal-support interaction-are all discussed. To evaluate the reactivity of the surface and understand the energetics of the process, density-functional theory calculations are used as a unique tool.

γ-Valerolactone Production from Levulinic Acid Hydrogenation Using Ni Supported Nanoparticles: Influence of Tungsten Loading and pH of Synthesis

γ-Valerolactone (GVL) has been considered an alternative as biofuel in the production of carbon-based chemicals; however, the use of noble metals and corrosive solvents has been a problem. In this work, Ni supported nanocatalysts were prepared to produce γ-Valerolactone from levulinic acid using methanol as solvent at a temperature of 170 °C utilizing 4 MPa of H₂. Supports were modified at pH 3 using acetic acid (CH₃COOH) and pH 9 using ammonium hydroxide (NH₄OH) with different tungsten (W) loadings (1%, 3%, and 5%) by the Sol-gel method. Ni was deposited by the suspension impregnation method. The catalysts were characterized by various techniques including XRD, N₂ physisorption, UV-Vis, SEM, TEM, XPS, H₂-TPR, and Pyridine FTIR. Based on the study of acidity and activity relation, Ni dispersion due to the Lewis acid sites contributed by W at pH 9, producing nanoparticles smaller than 10 nm of Ni, and could be responsible for the high esterification activity of levulinic acid (LA) to Methyl levulinate being more selective to catalytic hydrogenation. Products and by-products were analyzed by ¹H NMR. Optimum catalytic activity was obtained with 5% W at pH 9, with 80% yield after 24 h of reaction. The higher catalytic activity was attributed to the particle size and the amount of Lewis acid sites generated by modifying the pH of synthesis and the amount of W in the support due to the spillover effect.

Spherical Ni Nanoparticles Supported by Nanosheet-Assembled Al2O3 for Dry Reforming of CH4: Elucidating the Induction Period and Its Excellent Resistance to Coking

The design and preparation of efficient coking-resistant catalysts for dry reforming of methane (DRM) is significant for industrial applications but a challenge for supported Ni catalysts. Nanosheet-assembled Al₂O₃ (NA-Al₂O₃) with hierarchical hollow microspheres was used to support Ni nanoparticles, which exhibits superior long-time stability and coking resistance for the DRM reaction from 700 to 800 °C without coke deposition. Active Ni species, exsolved from NiAl₂O₄ spinel, are aggregated into Ni nanoparticles and finally stabilize as spherical Ni nanoparticles of 18.0 nm due to the spatial confinement of hierarchical hollow microspheres of the NA-Al₂O₃ support after the DRM reaction for 60 h. The catalytic activity in the induction period of the Ni/(NA-Al₂O₃) catalyst increases because of the enhancement of the surface Ni⁰/(Ni⁰+Ni²⁺) ratio, that is, the increment of the amount of active Ni sites. The spherical Ni nanoparticles embedded in the NA-Al₂O₃ support, superior CO₂ adsorption ability, and more surface hydroxyl groups on the Ni/(NA-Al₂O₃) catalyst are the determining factors for its long-time stability and excellent anti-coking for the DRM reaction.

Upgrading of Light Bio-oil from Solvothermolysis Liquefaction of an Oil Palm Empty Fruit Bunch in Glycerol by Catalytic Hydrodeoxygenation Using NiMo/Al2O3 or CoMo/Al2O3 Catalysts

Hydrodeoxygenation (HDO) of bio-oil derived from liquefaction of a palm empty fruit bunch (EFB) in glycerol was investigated. To enhance the heating value and reduce the oxygen content of upgraded bio-oil, hydrodeoxygenation of light bio-oil over Ni- and Co-based catalysts on an Al2O3 support was performed in a rotating-bed reactor. Two consecutive steps were conducted to produce bio-oil from EFB including (1) microwave-assisted wet torrefaction of EFB and (2) solvothermolysis liquefaction of treated EFB in a Na2CO3/glycerol system. The HDO of as-prepared bio-oil was subsequently performed in a unique design reactor possessing a rotating catalyst bed for efficient interaction of a catalyst with bio-oil and facile separation of the catalyst from upgraded bio-oil after the reaction. The reaction was carried out in the presence of each mono- or bimetallic catalyst, namely, Co/Al2O3, Ni/Al2O3, NiMo/Al2O3, and CoMo/Al2O3, packed in the rotating-mesh host with a rotation speed of 250 rpm and kept at 300 and 350 °C, 2 MPa hydrogen for 1 h. From the results, the qualities of upgraded bio-oil were substantially improved for all catalysts tested in terms of oxygen reduction and increased high heating value (HHV). Particularly, the NiMo/Al2O3 catalyst exhibited the most promising catalyst, providing favorable bio-oil yield and HHV. Remarkably greater energy ratios and carbon recovery together with high H/O, C/O, and H/C ratios were additionally achieved from the NiMo/Al2O3 catalyst compared with other catalysts. Cyclopentanone and cyclopentene were the main olefins found in hydrodeoxygenated bio-oil derived from liquefied EFB. It was observed that cyclopentene was first generated and subsequently converted to cyclopentanone under the hydrogenation reaction. These compounds can be further used as a building block in the synthesis of jet-fuel range cycloalkanes.

Higher Activity of Ni/γ-Al2O3 over Fe/γ-Al2O3 and Ru/γ-Al2O3 for Catalytic Ammonia Synthesis in Nonthermal Atmospheric-Pressure Plasma of N2 and H2

Developing a novel ammonia synthesis process from N2 and H2 is of interest to the catalysis and hydrogen research communities. γ-Alumina-supported nickel was determined capable of serving as an efficient catalyst for ammonia synthesis using nonthermal plasma under atmospheric pressure without heating. The catalytic activity was almost unrelated to the crystal structure and the surface area of the alumina carrier. The activity of Ni/Al2O3 was quantitatively compared with that of Fe/Al2O3 and Ru/Al2O3, which contained active metals for the conventional Haber–Bosch process. The activity sequence was Ni/Al2O3 > Al2O3 > Fe/Al2O3 > no additive > Ru/Al2O3, surprisingly indicating that the loading of Fe and Ru decreased the activity of Al2O3. The catalytic activity of Ni/Al2O3 was dependent on the amount of loaded Ni, the calcination temperature, and the reaction time. XRD, visual, and XPS observations of the catalysts before the plasma reaction indicated the generation of NiO and NiAl2O4 on Al2O3, the latter of which was generated upon high-temperature calcination. The NiO species was readily reduced to Ni metal in the plasma reaction, whereas the NiAl2O4 species was difficult to reduce. The catalytic behavior could be attributed to the production of fine Ni metal particles that served as active sites. The PN2/PH2 ratio dependence and rate constants of formation and decomposition of ammonia were finally determined for 5.0 wt% Ni/Al2O3 calcined at 773 K. The ammonia yield was 6.3% at an applied voltage of 6.0 kV, a residence time of reactant gases of 0.12 min, and PH2/PN2 = 1.

Hierarchical Fe-modified MgAl2O4 as a Ni-catalyst support for methane dry reforming

Hierarchical Fe-modified MgAl₂O₄ as a Ni-catalyst support with strong sintering resistance and anti-carbon ability for methane dry reforming.

Large Specific Surface Area Macroporous Nanocast LaFe1−xNixO3: A Stable Catalyst for Catalytic Methane Dry Reforming

Macroporous nanocast perovskites, LaFe1−xNixO3 (x = 0.3, 0.5, and 0.7), were synthesized by using a nanocasting technique with SBA-15 as a template and applied to methane dry reforming (MDR). The prepared catalysts were characterized by X-ray diffraction, transmission electron microscopy, specific-surface-area analysis, hydrogen temperature-programmed reduction, and thermogravimetric analysis. LaFe1−xNixO3 revealed a large specific surface area, which could enhance its catalytic activity. The catalysts were reduced to Ni/LaFeO3-La2O3 in the MDR reaction. The alkaline additive, La2O3, and perovskite oxide, LaFeO3, strongly interacted with the active component to reduce the surface energy of metal particles and prevent aggregation of active Ni. The results showed that LaFe0.5Ni0.5O3 and LaFe0.3Ni0.7O3 perform better than LaFe0.7Ni0.3O3. More importantly, LaFe0.5Ni0.5O3 had a very long lifetime (>80 h) in the MDR reaction. The LaFe0.5Ni0.5O3 catalyst showed excellent stability in the MDR reaction and has potential use in industrial applications.

Highly coke resistant Mg-Ni/Al2O3 catalyst prepared via a novel magnesiothermic reduction for methane reforming catalysis with CO2: the unique role of Al-Ni intermetallics

Addition of alkaline promoters is considered to be an effective way to improve the coking resistance of the metal/support composite catalysts for dry reforming of methane (DRM). The traditional metal/promoter/support composites for DRM catalysis are generally obtained from alkaline species impregnation and then high temperature H2 reduction. This two-step process leads to a random distribution of metal-promoter interaction. We herein report a novel magnesiothermic method to reduce Ni from spinel precursor and introduce alkaline Mg(ii) into the composite at the same time, which also gratifies the interaction between the promoter and metal nanoparticles (NPs). The reaction paths to Mg reduction are proposed. The as prepared catalysts show good activity and outstanding coking resistance in DRM. The Ni-Al intermetallics in the catalyst were found for the first time to play an important role in coking resistance as they can be in situ transformed into Ni nanoparticles and MgAl2O4 with strong metal-support interaction during the DRM.

Well-dispersed nickel nanoparticles on the external and internal surfaces of SBA-15 for hydrocracking of pyrolyzed α-cellulose

Catalysts comprising nickel supported on SBA-15 were prepared by wet impregnation and co-impregnation methods. Wet impregnation was performed by directly dispersing an Ni(NO3)2·6H2O aqueous solution into SBA-15, whereas in co-impregnation, ethylene glycol (EG) was added to nickel nitrate aqueous solution prior to dispersion into SBA-15. After drying and calcination, NiO/SBA-15w and NiO/SBA-15c were produced. Later, after the reduction process, Ni/SBA-15w and Ni/SBA-15c were obtained. The prepared catalysts were evaluated for the hydrocracking of pyrolyzed α-cellulose. The TEM images revealed that the catalysts prepared by wet impregnation showed inhomogeneous distribution of nickel loading, whereas catalysts prepared by co-impregnation using EG exhibited homogeneous distribution and formed no nickel aggregates. During hydrocracking of pyrolyzed α-cellulose, Ni/SBA-15c with total acidity, nickel loading, particle size, and specific surface area of 7.27 m mol g-1, 5.20 wt%, 3.17 nm, and 310.0 m2 g-1, respectively, exhibited the best catalytic performance compared to other prepared catalysts with 67.35 wt% conversion of liquid product with maximum selectivity in producing 13.09 wt% of 3-methyl-pentane. Moreover, Ni/SBA-15w with total acidity, nickel loading, particle size, and specific surface area of 10.87 m mol g-1, 8.15 wt%, 7.01 nm, and 628.0 m2 g-1, respectively, produced 69.89 wt% liquid product without hydrocarbons. Study of selectivity towards the formation of liquid hydrocarbons was carried out via double step hydrocracking using Ni/SBA-15w, and 18.55 wt% of n-hexane was produced in the liquid product.

Investigation of mesoporous NiAl2O4/MOx (M = La, Ce, Ca, Mg)–γ-Al2O3 nanocomposites for dry reforming of methane

Mesoporous NiAl₂O₄/MO_x (M = La, Ce, Ca, Mg)–γ-Al₂O₃ composites through a one-pot partial hydrolysis method showed excellent catalytic performance for dry reforming of methane.

Design, synthesis and applications of core-shell, hollow core, and nanorattle multifunctional nanostructures

With the evolution of nanoscience and nanotechnology, studies have been focused on manipulating nanoparticle properties through the control of their size, composition, and morphology. As nanomaterial research has progressed, the foremost focus has gradually shifted from synthesis, morphology control, and characterization of properties to the investigation of function and the utility of integrating these materials and chemical sciences with the physical, biological, and medical fields, which therefore necessitates the development of novel materials that are capable of performing multiple tasks and functions. The construction of multifunctional nanomaterials that integrate two or more functions into a single geometry has been achieved through the surface-coating technique, which created a new class of substances designated as core-shell nanoparticles. Core-shell materials have growing and expanding applications due to the multifunctionality that is achieved through the formation of multiple shells as well as the manipulation of core/shell materials. Moreover, core removal from core-shell-based structures offers excellent opportunities to construct multifunctional hollow core architectures that possess huge storage capacities, low densities, and tunable optical properties. Furthermore, the fabrication of nanomaterials that have the combined properties of a core-shell structure with that of a hollow one has resulted in the creation of a new and important class of substances, known as the rattle core-shell nanoparticles, or nanorattles. The design strategies of these new multifunctional nanostructures (core-shell, hollow core, and nanorattle) are discussed in the first part of this review. In the second part, different synthesis and fabrication approaches for multifunctional core-shell, hollow core-shell and rattle core-shell architectures are highlighted. Finally, in the last part of the article, the versatile and diverse applications of these nanoarchitectures in catalysis, energy storage, sensing, and biomedicine are presented.

Supported Ni catalyst on a natural halloysite derived silica–alumina composite oxide with unexpected coke-resistant stability for steam-CO2 dual reforming of methane

This work presents a facile and scalable approach for preparing robust supported Ni catalyst with unexpected catalytic stability with outstanding coke deposition and Ni-sintering resistance for steam-CO₂ dual reforming of methane to produce syngas.

Methane decomposition over unsupported mesoporous nickel ferrites: effect of reaction temperature on the catalytic activity and properties of the produced nanocarbon

Unsupported mesoporous nickel ferrites were successfully synthesized via a facile co-precipitation method and used for the thermocatalytic decomposition of methane into hydrogen and nanocarbon at various reaction temperatures.

A stable Ni/SBA-15 catalyst prepared by the ammonia evaporation method for dry reforming of methane

Coking and sintering were inhibited simultaneously by the strong metal–support interactions.

Effect of pore geometries on the catalytic properties of NiO–Al2O3 catalysts in CO2 reforming of methane

Mesoporous NiO–Al₂O₃ catalysts were prepared by an evaporation-induced self-assembly (EISA) method, during which the amount of HNO₃ added in the precursor solution was varied.

Structured Ni catalysts on porous anodic alumina membranes for methane dry reforming: NiAl2O4 formation and characterization

This communication presents the successful design of a structured catalyst based on porous anodic alumina membranes for methane dry reforming.

Influence of Ce2O3 and CeO2 promoters on Pd/MgO catalysts in the dry-reforming of methane

In this study, the conversion of methane and CO₂ to synthesis gas using dry reforming over Pd/MgO catalysts using different concentrations of Ce³⁺ and Ce⁴⁺ was investigated.