Catalytic partial oxidation of methane to syngas: review of perovskite catalysts and membrane reactors

Emerging trends in hydrogen and synfuel generation: a state-of-the-art review

The current work investigated emerging fields for generating and consuming hydrogen and synthetic Fischer-Tropsch (FT) fuels, especially from detrimental greenhouse gases, CO2 and CH4. Technologies for syngas generation ranging from partial oxidation, auto-thermal, dry, photothermal and wet or steam reforming of methane were adequately reviewed alongside biomass valorisation for hydrogen generation, water electrolysis and climate challenges due to methane flaring, production, storage, transportation, challenges and opportunities in CO2 and CH4 utilisation. Under the same conditions, dry reforming produces more coke than steam reforming. However, combining the two techniques produces syngas with a high H2/CO ratio, which is suitable for producing long-chain hydrocarbons. Although the steam methane reforming (SMR) process has been industrialised, it is well known to consume significant energy. However, coke production via catalytic methane decomposition, the prime hindrance to large-scale implementation of these techniques for hydrogen production, could be addressed by coupling CO with CO2 conversion to alter the H2/CO ratio of syngas, increasing the reaction temperatures in dry reforming, or increasing the steam content fed in steam reforming. Optimised hydrogen production and generation of green fuels from CO2 and CH4 can be achieved by implementing these strategies.

Development of Membrane Reactor Coupling Hydrogen and Syngas Production

Simultaneous syngas and pure hydrogen production through partial oxidation of methane and water splitting, respectively, were demonstrated by using mixed ionic-electronic conductors. Tubular ceramic membranes prepared from La_0.5Sr_0.5FeO₃ perovskite were successfully utilized in a 10 M lab scale reactor by applying a radial arrangement. The supply of methane to the middle area of the reaction zone was shown to provide a uniform distribution of the chemical load along the tubes' length. A steady flow of steam feeding the inner part of the membranes was used as oxidative media. A described configuration was found to be favorable to maintaining oxygen permeability values exceeding 1.1 mL∙cm^-2∙min^-1 and long-term stability of related functional characteristics. Methane's partial oxidation reaction assisted by 10%Ni@Al₂O₃ catalyst proceeded with selectivity values above 90% and conversion of almost 100%. The transition from a laboratory model of a reactor operating on one tubular membrane to a ten-tube one resulted in no losses in the specific performance. The optimized supply of gaseous fuel opens up the possibility of scaling up the reaction zone and creating a promising prototype of a multitubular reaction zone with a simplified sealing procedure.

Ni/(R2O3,CaO) Nanocomposites Produced by the Exsolution of R1.5Ca0.5NiO4 Nickelates (R = Nd, Sm, Eu): Rare Earth Effect on the Catalytic Performance in the Dry Reforming and Partial Oxidation of Methane

In order to clarify the role of R₂O₃ in the metal-oxide catalysts derived from complex oxide precursors, a series of R_1.5Ca_0.5NiO₄ (R = Nd, Sm, Eu) complex oxides was obtained. A significant systematic increase in the orthorhombic distortion of the R_1.5Ca_0.5NiO₄ structure (K₂NiF₄ type, Cmce) from Nd to Eu correlates with a corresponding decrease in their ionic radii. A reduction of R_1.5Ca_0.5NiO₄ in the Ar/H₂ gas mixture at 800 °C causes a formation of dense agglomerates of CaO and R₂O₃ coated with spherical 25-30 nm particles of Ni metal. The size of metal particles and oxide agglomerates is similar in all Ni/(R₂O₃,CaO) composites in the study. Their morphology is rather similar to the products of redox exsolution obtained by the partial reduction of complex oxides. All obtained composites demonstrated a significant catalytic activity in the dry reforming (DRM) and partial oxidation (POM) of methane at 700-800 °C. A systematic decrease in the DRM catalytic activity of composites from Nd to Eu could be attributed to the basicity reduction of R₂O₃ components of the composite catalysts. The maximum CH₄ conversion in POM reaction was observed for Ni/(Sm₂O₃,CaO), while the maximum selectivity was demonstrated by Nd₂O₃-based composite. The possible reasons for the observed difference are discussed.

Partial Oxidation of Methane over CaO Decorated TiO2 Nanocatalyst for Syngas Production in a Fixed Bed Reactor

Syngas is a valuable entity for downstream liquid fuel production and chemical industries. The efficient production of syngas via catalytic partial oxidation of methane (CPOM) is an important process. In this study, partial oxidation of methane (POM) was carried out using CaO decorated TiO2 catalysts. The catalysts were synthesized employing the sol-gel method, while the decoration of TiO2 with CaO was achieved in an aqueous solution by wetness impregnation method. The prepared catalysts were characterized by employing XRD, Raman, TG-DTG, and SEM-EDX for structural and morphological analysis. On testing for POM, at 750 °C the catalysts demonstrate excellent CH4 conversion of 83.6 and 79.5% for 2% and 3% CaO loaded TiO2, respectively. While the average H2/CO ratio for both 2% and 3% CaO loaded TiO2, 2.25 and 2.28, respectively, remained slightly above the theoretical value (H2/CO = 2.0) of POM. The improved POM performance is attributed to the optimally loaded CaO on the TiO2 surface that promotes the reaction where TiO2 support ensure less agglomerated particles, resulting into a fine distribution of the active catalytic sites.

Hydrogen Production from Coal Industry Methane

Coal industry methane is a fossil raw material that can serve as an energy carrier for the production of heat and electricity, as well as a raw material for obtaining valuable products for the chemical industry. To ensure the safety of coal mining, rational environmental management and curbing global warming, it is important to develop and improve methods for capturing and utilizing methane from the coal industry. This review looks at the scientific basis and promising technologies for hydrogen production from coal industry methane and coal production. Technologies for catalytic conversion of all types of coal industry methane (Ventilation Air Methane – VAM, Coal Mine Methane – CMM, Abandoned Mine Methane – AMM, Coal-Bed Methane – CBM), differing in methane concentration and methane-to-air ratio, are discussed. The results of studies on the creation of a number of efficient catalysts for hydrogen production are presented. The great potential of hybrid methods of processing natural coal and coal industry methane has been demonstrated.

Conversion of Methane with Oxygen to Produce Hydrogen Catalyzed by Triatomic Rh3 - Cluster Anion

Metal catalysts, especially noble metals, have frequently been prepared upon downsizing from nanoparticles to subnanoclusters to catalyze the important reaction of partial oxidation of methane (POM) in order to optimize the catalytic performance and conserve metal resources. Here, benefiting from mass spectrometric experiments in conjunction with photoelectron spectroscopy and quantum chemical calculations, we successfully determine that metal cluster anions composed of only three Rh atoms (Rh₃ ^-) can catalyze the POM reaction with O₂ to produce 2H₂ + CO₂ under thermal collision conditions (∼300 K). The interdependence between CH₄ and O₂ to protect Rh₃ ^- from collapse and to promote conversion of CH₄ → 2H₂ has been clarified. This study not only provides a promising metal cluster displaying good catalytic behavior in POM reaction under mild conditions but also reveals a strictly molecular-level mechanism of direct partial oxidation for the production of hydrogen, a promising renewable energy source in the 21st century.

Activation and catalytic transformation of methane under mild conditions

In the last few decades, worldwide scientists have been motivated by the promising production of chemicals from the widely existing methane (CH₄) under mild conditions for both chemical synthesis with low energy consumption and climate remediation. To achieve this goal, a whole library of catalytic chemistries of transforming CH₄ to various products under mild conditions is required to be developed. Worldwide scientists have made significant efforts to reach this goal. These significant efforts have demonstrated the feasibility of oxidation of CH₄ to value-added intermediate compounds including but not limited to CH₃OH, HCHO, HCOOH, and CH₃COOH under mild conditions. The fundamental understanding of these chemical and catalytic transformations of CH₄ under mild conditions have been achieved to some extent, although currently neither a catalyst nor a catalytic process can be used for chemical production under mild conditions at a large scale. In the academic community, over ten different reactions have been developed for converting CH₄ to different types of oxygenates under mild conditions in terms of a relatively low activation or catalysis temperature. However, there is still a lack of a molecular-level understanding of the activation and catalysis processes performed in extremely complex reaction environments under mild conditions. This article reviewed the fundamental understanding of these activation and catalysis achieved so far. Different oxidative activations of CH₄ or catalytic transformations toward chemical production under mild conditions were reviewed in parallel, by which the trend of developing catalysts for a specific reaction was identified and insights into the design of these catalysts were gained. As a whole, this review focused on discussing profound insights gained through endeavors of scientists in this field. It aimed to present a relatively complete picture for the activation and catalytic transformations of CH₄ to chemicals under mild conditions. Finally, suggestions of potential explorations for the production of chemicals from CH₄ under mild conditions were made. The facing challenges to achieve high yield of ideal products were highlighted and possible solutions to tackle them were briefly proposed.

Core-Shell Fe2O3@La1-xSrxFeO3-δ Material for Catalytic Oxidations: Coverage of Iron Oxide Core, Oxygen Storage Capacity and Reactivity of Surface Oxygens

A series of Fe2O3@LSF (La0.8Sr0.2FeO3-δ perovskite) core-shell materials (CSM) was prepared by infiltration of LSF precursors gel containing various complexants and their mixtures to nanocrystalline aggregates of hematite followed by thermal treatment. The content of LSF phase and amount of carboxyl groups in complexant determine the percent coverage of iron oxide core with the LSF shell. The most conformal coating core-shell material was prepared with citric acid as the complexant, contained 60 wt% LSF with 98% core coverage. The morphology of the CSM was studied by HRTEM-EELS combined with SEM-FIB for particles cross-sections. The reactivity of surface oxygen species and their amounts were determined by H2-TPR, TGA-DTG, the oxidation state of surface oxygen ions by XPS. It was found that at complete core coverage with perovskite shell, the distribution of surface oxygen species according to redox reactivity in CSM resemble pure LSF, but its lattice oxygen storage capacity is 2-2.5 times higher. At partial coverage, the distribution of surface oxygen species according to redox reactivity resembles that in iron oxide.

Oscillatory Behaviour of Ni Supported on ZrO2 in the Catalytic Partial Oxidation of Methane as Determined by Activation Procedure

Ni/ZrO₂ catalysts, active and selective for the catalytic partial oxidation of methane to syngas (CH₄-CPO), were prepared by the dry impregnation of zirconium oxyhydroxide (Z_hy) or monoclinic ZrO₂ (Z_m), calcination at 1173 K and activation by different procedures: oxidation-reduction (ox-red) or direct reduction (red). The characterization included XRD, FESEM, in situ FTIR and Raman spectroscopies, TPR, and specific surface area measurements. Catalytic activity experiments were carried out in a flow apparatus with a mixture of CH₄:O₂ = 2:1 in a short contact time. Compared to Z_m, Z_hy favoured the formation of smaller NiO particles, implying a higher number of Ni sites strongly interacting with the support. In all the activated Ni/ZrO₂ catalysts, the Ni-ZrO₂ interaction was strong enough to limit Ni aggregation during the catalytic runs. The catalytic activity depended on the activation procedures; the ox-red treatment yielded very active and stable catalysts, whereas the red treatment yielded catalysts with oscillating activity, ascribed to the formation of Ni^δ+ carbide-like species. The results suggested that Ni dispersion was not the main factor affecting the activity, and that active sites for CH₄-CPO could be Ni species at the boundary of the metal particles in a specific configuration and nuclearity.

Tailoring of a catalyst La0.8Ce0.1Ni0.4Ti0.6O3−δ interlayer via in situ exsolution for a catalytic membrane reactor

Tailored nickel nanoparticles on La_0.8Ce_0.1Ni_0.4Ti_0.6O_3−δ surfaces were prepared by in situ exsolution and used in the Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ catalytic membrane reactor for high-efficient partial oxidation of methane.