Development of Ni-Mo carbide catalyst for production of syngas and CNTs by dry reforming of biogas

Biogas has been widely regarded as a promising source of renewable energy. Recently, the direct conversion of biogas over heterogeneous catalysts for the simultaneous production of syngas and carbon nanotubes exhibits a high potential for full utilization of biogas with great benefits. Involving the combined dry reforming of methane and catalytic decomposition of methane, the efficiency of process is strongly depended on the catalyst activity/stability, mainly caused by carbon deposition. In this study, Ni-Mo catalyst is engineered to provide a life-long performance and perform high activity in the combined process. The surface modification of catalysts by a controlled carburization pretreatment is proposed for the first time to produce a carbide catalyst along with improving the catalyst stability as well as the reactivity for direct conversion of biogas. The performance of as-prepared carbide catalysts is investigated with comparison to the oxide and metallic ones. As a result, the Ni-Mo2C catalyst exhibited superior activity and stability over its counterparts, even though the condensed nanocarbon was largely grown and covered on the surface. In addition, up to 82% of CH4 conversion and 93% of CO2 conversion could remain almost constant at 800 °C throughout the entire test period of 3 h under a high flowrate inlet stream of pure biogas at 48,000 cm3 g-1 h-1. The XPS spectra of catalysts confirmed that the presence of Mo2C species on the catalyst surface could promote the stability and reactivity of the catalyst, resulting in higher productivity of carbon nanotubes over a longer time.

Effect of the Carbon Support and Conditions on the Carbothermal Synthesis of Cu-Molybdenum Carbide and Its Application on CO2 Hydrogenation to Methanol

The synthesis of methanol by carbon dioxide hydrogenation has been studied using copper-molybdenum carbides supported on high surface area graphite, reduced graphene oxide and carbon nanotubes. The synthesis conditions and the effect of the support were studied. The catalysts were prepared in situ using H₂ or He at 600 °C or 700 °C. Both molybdenum carbide and oxycarbide were obtained. A support with less reactive carbon resulted in lower proportion of carbide obtained. The best results were achieved over a 5 wt.% Cu and 10 wt.% Mo on high surface area graphite that reached 96.3% selectivity to methanol.

Elucidating the role of earth alkaline doping in perovskite-based methane dry reforming catalysts

To elucidate the role of earth alkaline doping in perovskite-based dry reforming of methane (DRM) catalysts, we embarked on a comparative and exemplary study of a Ni-based Sm perovskite with and without Sr doping. While the Sr-doped material appears as a structure-pure Sm_1.5Sr_0.5NiO₄ Ruddlesden Popper structure, the undoped material is a NiO/monoclinic Sm₂O₃ composite. Hydrogen pre-reduction or direct activation in the DRM mixture in all cases yields either active Ni/Sm₂O₃ or Ni/Sm₂O₃/SrCO₃ materials, with albeit different short-term stability and deactivation behavior. The much smaller Ni particle size after hydrogen reduction of Sm_1.5Sr_0.5NiO₄, and of generally all undoped materials stabilizes the short and long-term DRM activity. Carbon dioxide reactivity manifests itself in the direct formation of SrCO₃ in the case of Sm_1.5Sr_0.5NiO₄, which is dominant at high temperatures. For Sm_1.5Sr_0.5NiO₄, the CO : H₂ ratio exceeds 1 at these temperatures, which is attributed to faster direct carbon dioxide conversion to SrCO₃ without catalytic DRM reactivity. As no Sm₂O₂CO₃ surface or bulk phase as a result of carbon dioxide activation was observed for any material – in contrast to La₂O₂CO₃ – we suggest that oxy-carbonate formation plays only a minor role for DRM reactivity. Rather, we identify surface graphitic carbon as the potentially reactive intermediate. Graphitic carbon has already been shown as a crucial reaction intermediate in metal-oxide DRM catalysts and appears both for Sm_1.5Sr_0.5NiO₄ and NiO/monoclinic Sm₂O₃ after reaction as crystalline structure. It is significantly more pronounced for the latter due to the higher amount of oxygen-deficient monoclinic Sm₂O₃ facilitating carbon dioxide activation. Despite the often reported beneficial role of earth alkaline dopants in DRM catalysis, we show that the situation is more complex. In our studies, the detrimental role of earth alkaline doping manifests itself in the exclusive formation of the sole stable carbonated species and a general destabilization of the Ni/monoclinic Sm₂O₃ interface by favoring Ni particle sintering.

To elucidate the role of earth alkaline doping in perovskite-based dry reforming of methane (DRM) catalysts, we embarked on a comparative and exemplary study of a Ni-based Sm perovskite with and without Sr doping.

Metal (Mo, W, Ti) Carbide Catalysts: Synthesis and Application as Alternative Catalysts for Dry Reforming of Hydrocarbons-A Review

Dry reforming of hydrocarbons (DRH) is a pro-environmental method for syngas production. It owes its pro-environmental character to the use of carbon dioxide, which is one of the main greenhouse gases. Currently used nickel catalysts on oxide supports suffer from rapid deactivation due to sintering of active metal particles or the deposition of carbon deposits blocking the flow of gases through the reaction tube. In this view, new alternative catalysts are highly sought after. Transition metal carbides (TMCs) can potentially replace traditional nickel catalysts due to their stability and activity in DR processes. The catalytic activity of carbides results from the synthesis-dependent structural properties of carbides. In this respect, this review presents the most important methods of titanium, molybdenum, and tungsten carbide synthesis and the influence of their properties on activity in catalyzing the reaction of methane with carbon dioxide.

Mechanistic and multiscale aspects of thermo-catalytic CO2 conversion to C1 products

The increasing environmental concerns due to anthropogenic CO2 emissions have called for an alternate sustainable source to fulfill rising chemical and energy demands and reduce environmental problems. The thermo-catalytic activation and conversion of abundantly available CO2, a thermodynamically stable and kinetically inert molecule, can significantly pave the way to sustainably produce chemicals and fuels and mitigate the additional CO2 load. This can be done through comprehensive knowledge and understanding of catalyst behavior, reaction kinetics, and reactor design. This review aims to catalog and summarize the advances in the experimental and theoretical approaches for CO2 activation and conversion to C1 products via heterogeneous catalytic routes. To this aim, we analyze the current literature works describing experimental analyses (e.g., catalyst characterization and kinetics measurement) as well as computational studies (e.g., microkinetic modeling and first-principles calculations). The catalytic reactions of CO2 activation and conversion reviewed in detail are: (i) reverse water-gas shift (RWGS), (ii) CO2 methanation, (iii) CO2 hydrogenation to methanol, and (iv) dry reforming of methane (DRM). This review is divided into six sections. The first section provides an overview of the energy and environmental problems of our society, in which promising strategies and possible pathways to utilize anthropogenic CO2 are highlighted. In the second section, the discussion follows with the description of materials and mechanisms of the available thermo-catalytic processes for CO2 utilization. In the third section, the process of catalyst deactivation by coking is presented, and possible solutions to the problem are recommended based on experimental and theoretical literature works. In the fourth section, kinetic models are reviewed. In the fifth section, reaction technologies associated with the conversion of CO2 are described, and, finally, in the sixth section, concluding remarks and future directions are provided.

Stable and Antisintering Tungsten Carbides with Controllable Active Phase for Selective Cleavage of Aryl Ether C-O Bonds

Transition-metal carbides are important materials in heterogeneous catalysis. It remains challenging yet attractive in nanoscience to construct the active phase of carbide catalysts in a controllable manner and keep a sintering-resistant property in redox reactions, especially hydroprocessing. In this work, an integrated strategy was presented to synthesize stable and well-defined tungsten carbide nanoparticles (NPs) by assembling the metal precursor onto carbon nanotubes (CNTs), wrapping a thin polymeric layer, and following a controlled carburization. The polymer served as a soft carbon source to modulate the metal/carbon ratio in the carbides and introduced amorphous carbons around the carbides to prevent the NPs from sintering. The as-built p-W_xC/CNT displayed high stability in the hydrogenolysis of aryl ether C-O bond in guaiacol for more than 150 h. Its activity was more than two and six times higher than those prepared via typical temperature-programmed reduction with gaseous carbon (W_xC/CNT-TPR) and carbothermal reduction with intrinsic carbon support (W_xC/CNT-CTR), respectively. Our p-W_xC/CNT catalyst also achieved high efficiency for selective cleavage of the aryl ether C-O bonds in lignin-derived aromatic ethers, including anisole, dimethoxylphenol, and diphenyl ether, with a robust lifespan.

Carbothermally generated copper–molybdenum carbide supported on graphite for the CO2 hydrogenation to methanol

The carbothermal synthesis of monometallic and bimetallic molybdenum carbide and copper supported on high surface area graphite, has been studied at 600 and 700 °C and characterised. The catalysts were tested for CO₂ hydrogenation to CH₃OH.

Steering the Methane Dry Reforming Reactivity of Ni/La2O3 Catalysts by Controlled In Situ Decomposition of Doped La2NiO4 Precursor Structures

The influence of A- and/or B-site doping of Ruddlesden-Popper perovskite materials on the crystal structure, stability, and dry reforming of methane (DRM) reactivity of specific A2BO4 phases (A = La, Ba; B = Cu, Ni) has been evaluated by a combination of catalytic experiments, in situ X-ray diffraction, X-ray absorption spectroscopy (XAS), X-ray photoelectron spectroscopy (XPS), and aberration-corrected electron microscopy. At room temperature, B-site doping of La2NiO4 with Cu stabilizes the orthorhombic structure (Fmmm) of the perovskite, while A-site doping with Ba yields a tetragonal space group (I4/mmm). We observed the orthorhombic-to-tetragonal transformation above 170 °C for La2Ni0.9Cu0.1O4 and La2Ni0.8Cu0.2O4, slightly higher than for undoped La2NiO4. Loss of oxygen in interstitial sites of the tetragonal structure causes further structure transformations for all samples before decomposition in the temperature range of 400 °C-600 °C. Controlled in situ decomposition of the parent or A/B-site doped perovskite structures in a DRM mixture (CH4:CO2 = 1:1) in all cases yields an active phase consisting of exsolved nanocrystalline metallic Ni particles in contact with hexagonal La2O3 and a mixture of (oxy)carbonate phases (hexagonal and monoclinic La2O2CO3, BaCO3). Differences in the catalytic activity evolve because of (i) the in situ formation of Ni-Cu alloy phases (in a composition of >7:1 = Ni:Cu) for La2Ni0.9Cu0.1O4, La2Ni0.8Cu0.2O4, and La1.8Ba0.2Ni0.9Cu0.1O4, (ii) the resulting Ni particle size and amount of exsolved Ni, and (iii) the inherently different reactivity of the present (oxy)carbonate species. Based on the onset temperature of catalytic DRM activity, the latter decreases in the order of La2Ni0.9Cu0.1O4 ∼ La2Ni0.8Cu0.2O4 ≥ La1.8Ba0.2Ni0.9Cu0.1O4 > La2NiO4 > La1.8Ba0.2NiO4. Simple A-site doped La1.8Ba0.2NiO4 is essentially DRM inactive. The Ni particle size can be efficiently influenced by introducing Ba into the A site of the respective Ruddlesden-Popper structures, allowing us to control the Ni particle size between 10 nm and 30 nm both for simple B-site and A-site doped structures. Hence, it is possible to steer both the extent of the metal-oxide-(oxy)carbonate interface and its chemical composition and reactivity. Counteracting the limitation of the larger Ni particle size, the activity can, however, be improved by additional Cu-doping on the B-site, enhancing the carbon reactivity. Exemplified for the La2NiO4 based systems, we show how the delicate antagonistic balance of doping with Cu (rendering the La2NiO4 structure less stable and suppressing coking by efficiently removing surface carbon) and Ba (rendering the La2NiO4 structure more stable and forming unreactive surface or interfacial carbonates) can be used to tailor prospective DRM-active catalysts.

Finding of a new cycle route in Ni/Mo2C catalyzed CH4–CO2 reforming

A new cycle route of Ni/Mo₂C ↔ MoNi₄ is firstly confirmed in a Ni/Mo₂C catalyzed CH₄–CO₂ reforming reaction.

Novel synthesis of a NiMoP phosphide catalyst via carbothermal reduction for dry reforming of methane

NiMoP-Glu with small particle size and an appropriate carbon content showed higher catalytic activity and stability than NiMoP-H2.

Transition Metal Carbides (TMCs) Catalysts for Gas Phase CO2 Upgrading Reactions: A Comprehensive Overview

Increasing demand for CO2 utilization reactions and the stable character of CO2 have motivated interest in developing highly active, selective and stable catalysts. Precious metal catalysts have been studied extensively due to their high activities, but their implementation for industrial applications is hindered due to their elevated cost. Among the materials which have comparatively low prices, transition metal carbides (TMCs) are deemed to display catalytic properties similar to Pt-group metals (Ru, Rh, Pd, Ir, Pt) in several reactions such as hydrogenation and dehydrogenation processes. In addition, they are excellent substrates to disperse metallic particles. Hence, the unique properties of TMCs make them ideal substitutes for precious metals resulting in promising catalysts for CO2 utilization reactions. This work aims to provide a comprehensive overview of recent advances on TMCs catalysts towards gas phase CO2 utilization processes, such as CO2 methanation, reverse water gas shift (rWGS) and dry reforming of methane (DRM). We have carefully analyzed synthesis procedures, performances and limitations of different TMCs catalysts. Insights on material characteristics such as crystal structure and surface chemistry and their connection with the catalytic activity are also critically reviewed.

Binary and ternary transition metal phosphides for dry reforming of methane

Mo-based phosphides showed higher activity for CH₄–CO₂ reforming than Fe₂P, WP, CoP and Ni₂P.

The Relationship between Reaction Temperature and Carbon Deposition on Nickel Catalysts Based on Al2O3, ZrO2 or SiO2 Supports during the Biogas Dry Reforming Reaction

The tackling of carbon deposition during the dry reforming of biogas (BDR) necessitates research of the surface of spent catalysts in an effort to obtain a better understanding of the effect that different carbon allotropes have on the deactivation mechanism and correlation of their formation with catalytic properties. The work presented herein provides a comparative assessment of catalytic stability in relation to carbon deposition and metal particle sintering on un-promoted Ni/Al2O3, Ni/ZrO2 and Ni/SiO2 catalysts for different reaction temperatures. The spent catalysts were examined using thermogravimetric analysis (TGA), Raman spectroscopy, high angle annular dark field scanning transmission electron microscopy (STEM-HAADF) and X-ray photoelectron spectroscopy (XPS). The results show that the formation and nature of carbonaceous deposits on catalytic surfaces (and thus catalytic stability) depend on the interplay of a number of crucial parameters such as metal support interaction, acidity/basicity characteristics, O2– lability and active phase particle size. When a catalytic system possesses only some of these beneficial characteristics, then competition with adverse effects may overshadow any potential benefits.

Simple and large-scale synthesis of β-phase molybdenum carbides as highly stable catalysts for dry reforming of methane

The catalytic stability of monometallic β-Mo₂C/CNTs was found to be superior to that of bimetallic Ni/β-Mo₂C under similar reaction conditions.

Improvement of the catalytic stability of molybdenum carbide via encapsulation within carbon nanotubes in dry methane reforming

We reported for the first time the enhancement of the oxidation resistance of Mo₂C nanoparticles by encapsulation within carbon nanotubes (CNTs).

Simple synthesis of ultrasmall β-Mo2C and α-MoC1−x nanoparticles and new insights into their catalytic mechanisms for dry reforming of methane

Ultrasmall β- and α-molybdenum carbide particles were synthesized by a resin route and they showed different oxidation–recarburization cycles.

Effect of a second metal (Co, Cu, Mn or Zr) on nickel catalysts derived from hydrotalcites for the carbon dioxide reforming of methane

NiCo and NiCu catalysts exhibited enhanced stability compared with a Ni catalyst for the dry reforming of methane. On the contrary, NiMn and NiZr catalysts decreased the reforming stability.

Molybdenum phosphide as a novel and stable catalyst for dry reforming of methane

A novel MoP catalyst exhibited high coking and oxidation resistance for dry reforming of CH₄with CO₂.