Partial Oxidation of Bio-methane over Nickel Supported on MgO-ZrO2 Solid Solutions

Syngas can be produced from biomethane via Partial Oxidation of Methane (POM), being an attractive route since it is ecofriendly and sustainable. In this work, catalysts of Ni supported on MgO-ZrO2 solid solutions, prepared by a one-step polymerization method, were characterized by HRTEM/EDX, XRD, XPS, H2-TPR, and in situ XRD. All catalysts, including Ni/ZrO2 and Ni/MgO as reference, were tested for POM (CH4:O2 molar ratio 2, 750 ºC, 1 atm). NiO/MgO/ZrO2 contained two solid-solutions, MgO-ZrO2 and NiO-MgO, as revealed by XRD and XPS. Ni (30 wt%) supported on MgO-ZrO2 solid solution exhibited high methane conversion and hydrogen selectivity. However, depending on the MgO amount (0, 4, 20, 40, 100 molar percent) major differences in NiO reducibility, growth of Ni0 crystallite size during H2 reduction and POM, and in carbon deposition rates were observed. Interestingly, catalysts with lower MgO content achieved the highest CH4 conversion (~ 95%), high selectivity to H2 (1.7) and CO (0.8), and low carbon deposition rates (0.024 g carbon.gcat-1 h-1) with Ni4MgZr (4 mol% MgO) turning out to be the best catalyst. In situ XRD during POM indicated metallic Ni nanoparticles (average crystallite size of 31 nm), supported by MgO-ZrO2 solid solution, with small amounts of NiO-MgO being present as well. The presence of MgO also influenced the morphology of the carbon deposits, leading to filaments instead of amorphous carbon. A combustion-reforming mechanism is suggested and using a MgO-ZrO2 solid solution support strongly improves catalytic performance, which is attributed to effective O2, CO2 and H2O activation at the Ni/MgO-ZrO2 interface.

Influence of Lanthanum Precursor on the Activity of Nickel Catalysts in the Mixed-Methane Reforming Process

This work investigated the influence of the catalytic support precursor on the activity of nickel catalysts 20%Ni/5%La₂O₃-95%Al₂O₃ in the mixed methane reforming process. The activity tests were carried out at a temperature of 750 °C. The research showed that the catalyst prepared from the precursor containing chloride exhibited very low conversions of methane and carbon dioxide. The poisoned catalyst system before and after the calcination process was subjected to Temperature Programmed Surface Reaction tests to determine whether the thermal treatment causes a decrease in the amount of chlorine in the system. To determine the decomposition temperature of the LaCl₃ precursor and the nickel chloride NiCl₂ compound, the samples were analyzed by Thermogravimetry. Finally, the catalytic samples were tested by Time-of-Flight Secondary Ion Mass Spectrometry analysis to confirm the presence of nickel-chlorine bonds on the surface of the catalytic system.

Effect of Support on Stability and Coke Resistance of Ni-Based Catalyst in Combined Steam and CO2 Reforming of CH4

Ni-based catalysts dispersed on different supports (MgO-α-Al₂O₃, CeO₂, SBA-15, and MgO-SBA-15) were prepared by the impregnation method. Characteristics of the catalysts, including specific surface areas (N₂ physisorption), crystalline phase compositions (powder X-ray diffraction, Raman spectroscopy), reducibility (hydrogen temperature-programmed reduction, H₂-TPR), and morphology (scanning electron microscopy (SEM) and transmission electron microscopy, TEM)) were investigated. The activity and stability of the catalysts were tested for the combined steam and CO₂ reforming of methane at 700 °C in a microflow system. The results show that the catalysts exhibit high activity in the BRM reaction. At 700 °C, the conversion of CH₄ and CO₂ reached 86-99% and 67-80%, respectively, in which the Ni/Mg-SBA catalyst is the best with conversions of CH₄ and CO₂ reaching 99% and 80%. Coke accumulation on the surface of the catalysts for 100 h time on stream (TOS) was evaluated by the temperature-programmed oxidation (TPO) technique. The major cause of the catalytic deactivation was elucidated by combining the determination of the amount and type of deposited coke with the changes in the physicochemical properties of the catalysts after the long-term reaction. Almost complete loss of activity was observed on Ni/Mg-Al catalyst after 100 h TOS, while the activity drop was slow on the Ni/Mg-SBA sample, about 15-20% of the total value. Otherwise, the Ni/CeO₂ and Ni/SBA catalysts firmly retained their stable activity for 100 h TOS due to the minimal carbon deposition and stability of these catalysts' structure. The highly considerable formation of inert C_γ carbon and sintering over Ni catalyst supported on MgO-α-Al₂O₃ were responsible for the lower stability of this catalyst compared to those supported on CeO₂ and SBA-15.

Optimizing MgO Content for Boosting γ-Al2O3-Supported Ni Catalyst in Dry Reforming of Methane

The dry reforming of methane (DRM) process has attracted research interest because of its ability to mitigate the detrimental impacts of greenhouse gases such as methane (CH4) and carbon dioxide (CO2) and produce alcohols and clean fuel. In view of this importance of DRM, we disclosed the efficiency of a new nickel-based catalyst, which was promoted with magnesia (MgO) and supported over gamma-alumina (γ-Al2O3) doped with silica (SiO2), toward DRM. The synthesized catalysts were characterized by H2 temperature-programmed reduction (H2-TPR), X-ray diffraction (XRD), X-ray Photoelectron Spectroscopy (XPS), Thermogravimetric analysis (TGA), and Transmission electron microscopy (TEM) techniques. The effect of MgO weight percent loading (0.0, 1.0, 2.0, and 3.0 wt. %) was examined because the catalytic performance was found to be a function of this parameter. An optimum loading of 2.0 wt. % of MgO was obtained, where the conversion of CH4 and CO2 at 800 °C were 86% and 91%, respectively, while the syngas (H2/CO) ratios relied on temperature and were in the range of 0.85 to 0.95. The TGA measurement of the best catalyst, which was operated over a 15-h reaction time, displayed negligible weight loss (<9.0 wt. %) due to carbon deposition, indicating the good resistance of our catalyst system to the deposition of carbon owing to the dopant and the modifier. TEM images showed the presence of multiwalled carbon nanotubes, confirming the TGA.

Single-Step Flame Aerosol Synthesis of Active and Stable Nanocatalysts for the Dry Reforming of Methane

We introduce a flame-based aerosol process for producing supported non-noble metal nanocatalysts from inexpensive aqueous metal salt solutions, using catalysts for the dry reforming of methane (DRM) as a prototype. A flame-synthesized nickel-doped magnesia (MgO) nanocatalyst (NiMgO-F) was fully physicochemically characterized and tested in a flow reactor system, where it showed stable DRM activity from 500 to 800 °C. A kinetic study was conducted, and apparent activation energies were extracted for the temperature range of 500-650 °C. It was then compared with a Ni-decorated MgO nanopowder prepared by wet impregnation of (1) flame-synthesized MgO (NiMgO-FI) and (2) a commercial MgO nanopowder (NiMgO-CI) and with (3) a NiMgO catalyst prepared by co-precipitation (NiMgO-CP). NiMgO-F showed the highest catalytic activity per mass and per metallic surface area and was stable for continuous H₂ production at 700 °C for 50 h. Incorporation of potential promoters and co-catalysts was also demonstrated, but none showed significant performance improvement. More broadly, nanomaterials produced by this approach could be used as binary or multicomponent catalysts for numerous catalytic processes.

Sinter-resistant Rh nanoparticles supported on γ-Al2O3 nanosheets as an efficient catalyst for dry reforming of methane

γ-Al2O3 nanosheet supported rhodium catalysts with Rh loadings between 0.05 and 2 wt% were prepared by the impregnation method and used for dry reforming of methane (DRM). It was found that Rh species on γ-Al2O3 nanosheets demonstrated excellent stability against sintering at high temperature. After calcining in air at 800 °C followed by reducing with hydrogen at 600 °C, the average particle size of Rh at maximum distribution increases from 1.0 ± 0.3 to 1.8 ± 0.3 nm with an increase in Rh loadings in the catalysts from 0.05 to 2 wt%. Even after reducing with hydrogen at 900 °C, the average size of Rh particles in the catalysts still remained below 2 nm. The results of catalytic performance evaluation show that CH4 and CO2 conversions of 84% and 90%, respectively, with a H2/CO ratio in syngas close to unity can be achieved with a catalyst of Rh loading of only 0.05 wt% at 750 °C. The performance of the catalyst remains stable for more than 200 h. No significant aggregation of the Rh particles is observed on the catalyst after the reaction. The results of XPS, H2-TPR and O2-TPD characterization methods indicate that the strong interaction between Rh and the γ-Al2O3 nanosheets plays a key role in increasing the dispersion of Rh species in the catalyst and preventing it from sintering under high temperature conditions. This factor is also responsible for the superior activity and stability of the catalyst with extremely low Rh loading for the DRM reaction.

Response to Comment on "Dry reforming of methane by stable Ni-Mo nanocatalysts on single-crystalline MgO"

Hu and Ruckenstein state that our findings were overclaimed and not new, despite our presentation of evidence for the Nanocatalysts on Single Crystal Edges (NOSCE) mechanism. Their arguments do not take into account fundamental differences between our Ni-Mo/MgO catalyst and their NiO/MgO preparations.

A Facile and Scalable Approach to Ultrathin NixMg1−xO Solid Solution Nanoplates and Their Performance for Carbon Dioxide Reforming of Methane

Carbon dioxide reforming of methane (CRM) represents a promising method that can effectively convert CH4 and CO2 into valuable energy resources. Herein, ultrathin NixMg1−xO nanoplate catalysts were synthesized using a scalable and facile process involving a one-pot, co-precipitation method in the absence of surfactants. This approach resulted in the synthesis of planar NixMg1−xO catalysts that were much thinner (˂8 nm) with larger specific surface area (>120 m2/g) in comparison to NixMg1−xO catalysts prepared by conventional methods. The ultrathin NixMg1−xO nanoplate catalysts exhibited high thermal stability, catalytic activity, and durability for CRM. Especially, these novel catalysts exhibited excellent anti-coking behavior with a low carbon deposition of 2.1 wt.% after 36 h of continuous reaction compared with the conventional catalysts, under the reaction conditions of the present study. The improved performance of the thin NixMg1−xO nanoplate catalysts was attributed to the high specific surface area and the interaction between metallic nickel nanocatalysts and the solid solution substrates to stabilize the Ni nanoparticles.

Syngas production by bi-reforming methane on an Ni–K-promoted catalyst using hydrotalcites and filamentous carbon as a support material

Steam reforming of methane (SRM) and dry reforming of methane (DRM) are frequently used in the production of syngas; however, the bi-reforming of methane (BRM) is an interesting and alternative process. In this study, BRM was studied over MgO, a layered double hydroxide (LDH) phase that was destroyed between 600 °C and 900 °C during the reaction. It showed good sorption capacity for CO₂ at relatively low temperatures (<500 °C), with CO₂ adsorption being a pre-requisite for its catalytic conversion. Among the tested materials, the potassium-promoted LDH showed the highest activity, achieving a maximum CO₂ conversion of 75%. The results suggest that at high temperature, the electronic structure of the used materials influences the destabilization of the feed in the order of methane, water and carbon dioxide. K promotes the catalytic activity, compensates the presence of large Ni particle sizes originating from the high metal loading, and favors the formation of Mg–Al-spinel. K is known to be an electronic promoter that releases electrons, which flow to the active metal. This electron flow induces instability on the molecule to be converted, and most probably, also induces size variations on the respective active nickel metal. The influence of the operating conditions in the range of 300 °C to 900 °C on the conversion of the reactants and product distribution was studied. Accordingly, it was concluded that it is only possible to obtain molar ratios of hydrogen-to-carbon monoxide close to two at high temperatures, a pre-requisite for the synthesis of methanol.

A Ni phase dispersed in CO₂ is used with a K promoter in the BRM. The LDH support structure collapses at high temperatures, inducing large Ni crystal sizes, and disfavoring activity. The catalyst is compensated by the K promoter, and the formation of an Mg–Al-spinel.

Exfoliated Molybdenum Disulfide as a Platform for Carbon Nanotube Growth-Properties and Characterization

Carbon nanotubes (CNTs) have been of great interest because of their unique electrical, structural, and mechanical properties. Many methods for obtaining CNTs are known. Chemical vapor deposition (CVD) has been recognized as the most popular and practical synthetic method for obtaining CNTs, with high purity, high yield, and low cost. Catalyst components are usually transient metals such as Fe, Co, and Ni, and hydrocarbons are used as a feedstock for the CNT synthesis. The metal particles are supported on the inorganic porous materials, such as alumina (Al₂O₃), silica (SiO₂), magnesia (MgO), zeolite, and mesoporous silica. In this work, we propose a new platform for the deposition of metal nanoparticles and the growth of CTs. Molybdenum disulfide (MoS₂) has gained much attention in the material fields. The principal aim of the present work is to compare the synergetic effect of MoS₂ and CTs and to investigate the possibility of using the material in various fields. The obtained material was tested for its use in fire retardation. We compared the effect of adding bulk MoS₂ and MoS₂/CTs into the polymer matrix.

A thermo-photo hybrid process for steam reforming of methane: highly efficient visible light photocatalysis

Steam reforming of methane (SRM) is one of the most important industrial processes, which produces 95% of hydrogen used in the USA. However, SRM is an endothermic reaction, which requires a high energy input and a high reaction temperature (>800 °C) for the current process. Furthermore, its products must be subjected to a water-gas shift (WGS) process. A photocatalytic process is expected to solve the energy issue and to eliminate the necessity of WGS for SRM. However, the hydrogen yield from the current photocatalytic steam reforming of methane (PSRM) is very low (μmol h^-1 g^-1 level), which is far below industrial interest. This work demonstrates that a Pt/blackTiO₂ catalyst dispersed on a light-diffuse-reflection-surface is excellent for efficient visible-light PSRM. Under visible light illumination on the catalyst by filtering UV light from AM 1.5G sunlight, CH₄ and H₂O were directly converted into H₂ and CO₂ without WGS, leading to a high H₂ yield of 185 mmol h^-1 g^-1 with a quantum efficiency of 60% at 500 °C. The yield is 3 orders of magnitude larger than the reported values, which can be attributed to the synergistic effect between potential and kinetic energies. This opens up a new opportunity for hydrogen production from water and natural gas using solar energy.

Carbon Formation Mechanism of C2H2 in Ni-Based Catalysts Revealed by in Situ Electron Microscopy and Molecular Dynamics Simulations

Understanding the carbon formation mechanism is critical for designing catalysts in various applications. Here, we report the observation of the carbon formation mechanism on Ni-based catalysts by environmental transmission electron microscopy (ETEM) over a wide temperature range in combination with molecular dynamics simulations and density functional theory calculations. In situ TEM observation performed in a C₂H₂/H₂ atmosphere provides real-time evidence that Ni₃C is an intermediate phase that decomposes to graphitic carbon and metallic Ni, leading to carbon formation. Mechanisms of acetylene decomposition and evolution of carbon atom configuration are revealed by molecular dynamics simulations, which corroborate the experimental results. The modification of MgO on NiO can effectively decrease the formation of graphitic layers and thus enhance the catalytic performance of NiO. This finding may provide an insight into the origin of the carbon deposition and aid in developing effective approaches to mitigate it.

Influence of Nature Support on Methane and CO2 Conversion in a Dry Reforming Reaction over Nickel-Supported Catalysts

A promising method to reduce global warming has been methane reforming with CO2, as it combines two greenhouse gases to obtain useful products. In this study, Ni-supported catalysts were synthesized using the wet impregnation method to obtain 5%Ni/Al2O3(SA-5239), 5%Ni/Al2O3(SA-6175), 5%Ni/SiO2, 5%Ni/MCM41, and 5%Ni/SBA15. The catalysts were tested in dry reforming of methane at 700 °C, 1 atm, and a space velocity of 39,000 mL/gcat h, to study the interaction of Ni with the supports, and evaluation was based on CH4 and CO2 conversions. 5%Ni/Al2O3(SA-6175) and 5%Ni/SiO2 gave the highest conversion of CH4 (78 and 75%, respectively) and CO2 (84 and 82%, respectively). The catalysts were characterized by some techniques. Ni phases were identified by X-ray diffraction patterns. Brunauer-Emmett-Teller analysis showed different surface areas of the catalysts with the least being 4 m2/g and the highest 668 m2/g belonging to 5%Ni/Al2O3(SA-5239) and 5%Ni/SBA15, respectively. The reduction profiles revealed weak NiO-supports interaction for 5%Ni/Al2O3(SA-5239), 5%Ni/MCM41, and 5%Ni/SBA15; while strong interaction was observed in 5%Ni/Al2O3(SA-6175) and 5%Ni/SiO2. The 5%Ni/Al2O3(SA-6175) and 5%Ni/SiO2 were close with respect to performance; however, the former had a higher amount of carbon deposit, which is mostly graphitic, according to the conducted thermal analysis. Carbon deposits on 5%Ni/SiO2 were mainly atomic in nature.

Topologically immobilized catalysis centre for long-term stable carbon dioxide reforming of methane

A rooted catalyst, Ni#Y₂O₃, successfully inhibits the growth of carbon nanotubes in DRM.

Methane reforming at low temperatures is of growing importance to mitigate the environmental impact of the production of synthesis gas, but it suffers from short catalyst lifetimes due to the severe deposition of carbon byproducts. Herein, we introduce a new class of topology-tailored catalyst in which tens-of-nanometer-thick fibrous networks of Ni metal and oxygen-deficient Y₂O₃ are entangled with each other to form a rooted structure, i.e., Ni#Y₂O₃. We demonstrate that the rooted Ni#Y₂O₃ catalyst stably promotes the carbon-dioxide reforming of methane at 723 K for over 1000 h, where the performance of traditional supported catalysts such as Ni/Y₂O₃ diminishes within 100 h due to the precluded mass transport by accumulated carbon byproducts. In situ TEM demonstrates that the supported Ni nanoparticles are readily detached from the support surface in the reaction atmosphere, and migrate around to result in widespread accumulation of the carbon byproducts. The long-term stable methane reforming over the rooted catalyst is ultimately attributed to the topologically immobilized Ni catalysis centre and the synergistic function of the oxygen-deficient Y₂O₃ matrix, which successfully inhibits the accumulation of byproducts.

CO2 reforming of CH4 on Ni-Al-Ox catalyst using pure and coal gas feeds: Synergetic effect of CoO and MgO in mitigating carbon deposition

Mg-Al-Ox supported monometallic (Ni) and bimetallic (Ni-Co) catalysts with different compositions of Mg and Al were investigated for CO₂ reforming of CH₄, using both coal and pure gas feeds, to limit the emission of these environmental pollutant gases into the atmosphere. Results showed that all the catalysts were active for dry reforming reaction using both feeds. Reactants conversion, stoichiometric product selectivity, and resistance to carbon deposition of catalysts remarkably improved when the Mg/Al ratio was greater than 1. Characterization results revealed changes in the bulk structure, textural and surface properties as the Mg/Al ratio and composition of catalysts changed. Improved active metal reduction, metal-support and metal-metal interaction (in the bimetallic) were also noted in the catalysts with Mg/Al ratio greater than 1. With respect to feed composition, less carbon deposition was recorded in the corresponding catalysts using coal gas compared to the pure gas. Ni-Co interaction and their interaction with MgO facilitated better basicity, increased metal dispersion and smaller particle size in Ni-Co-Mg_1.7-Al₁-Ox, which showed best catalytic performance with no carbon deposition in both feeds. These interactions and properties stabilized the Ni site, which made the Ni-Co-Mg_1.7-Al₁-Ox, catalyst resistant to sintering and carbon deposition.

Methane Dry Reforming over Ni-Co/Al2O3: Kinetic Modelling in a Catalytic Fixed-bed Reactor

The dry reforming of CH4 was investigated in a catalytic fixed-bed reactor to produce hydrogen at different temperatures over supported bimetallic Ni-Co catalyst. The reactor model for the dry reforming of methane used a set of kinetic models: The Zhang et al model for the dry reforming of methane (DRM); the Richardson-Paripatyadar model for the reverse water gas shift (RWGS); and the Snoeck et al kinetics for the coke-deposition and gasification reactions. The effect of temperatures on the performance of the reactor was studied. The amount of each species consumed or/and produced were calculated and compared with the experimental determined ones. It was showed that the set of kinetic model used in this work gave a good fit and accurately predict the experimental observed profiles from the fixed bed reactor. It was found that reaction-4 and reaction-5 could be neglected which could explain the fact that this catalyst coked rapidly comparatively with other catalyst. The use of large amount of Ni-Co will lead to carbon deposition and so to the catalyst deactivation.

Microemulsion based synthesis of Ni/MgO catalyst for dry reforming of methane

The dry reforming of methane has been investigated with two sets of catalysts (pure Ni and Ni/MgO) prepared by microemulsion system.

Highly stable mesoporous NiO–Y2O3–Al2O3 catalysts for CO2 reforming of methane: effect of Ni embedding and Y2O3 promotion

A series of mesoporous NiO–Y₂O₃–Al₂O₃ composite oxides with different yttrium contents were synthesized by either a one-pot evaporation-induced self-assembly (EISA) method or impregnation for carbon dioxide reforming of methane (CRM).