Recent Scientific Progress on Developing Supported Ni Catalysts for Dry (CO2) Reforming of Methane

Metal-Organic Framework-Templated Synthesis of Nickel-Alumina Nanocatalysts Improves Catalyst-Support Interaction for Higher Activity and Stability in Biogas Reforming under Controlled Oxidizing Conditions

Tri-reforming methane with CO2, O2, and H2O mixtures requires a delicate balance of dry-reforming, partial oxidation, and steam-reforming reactions to improve the CO2 conversion and H2/CO ratio. Nickel-alumina has been reported before for the tri-reforming of methane, although at higher temperatures (>900 °C). This is because the current approaches for nickel-alumina synthesis are ineffective in generating stronger catalyst-support interactions necessary to maintain higher active sites and stall carbon nanotube (CNT) deposition. Here, we report a synthesis method that allows controlled loading of nickel on alumina-based MIL-53 metal-organic framework followed by calcination to generate 2.5-10 wt % nickel nanoparticles dispersed on alumina. The 5 wt % nickel-alumina mixtures resulted in nanometer-sized crystallites, better metal dispersion, and more active sites for enhanced catalytic activity. This optimal loading of nickel allows stronger interaction with alumina for over 100 h of stable performance of tri-reforming at 800 °C, achieving ∼98% CH4 conversion, ∼36% CO2 conversion, and no carbon deposition while producing Fischer-Tropsch-ready feed containing a H2/CO ratio of 3.2.

A review on high-pressure heterogeneous catalytic processes for gas-phase CO2 valorization

This review discusses the importance of mitigating CO2 emissions by valorizing CO2 through high-pressure catalytic processes. It focuses on various key processes, including CO2 methanation, reverse water-gas shift, methane dry reforming, methanol, and dimethyl ether synthesis, emphasizing pros and cons of high-pressure operation. CO2 methanation, methanol synthesis, and dimethyl ether synthesis reactions are thermodynamically favored under high-pressure conditions. However, in the case of methane dry reforming and reverse water-gas shift, applying high pressure, results in decreased selectivity toward desired products and an increase in coke production, which can be detrimental to both the catalyst and the reaction system. Nevertheless, high-pressure utilization proves industrially advantageous for cost reduction when these processes are integrated with Fischer-Tropsch or methanol synthesis units. This review also compiles recent advances in heterogeneous catalysts design for high-pressure applications. By examining the impact of pressure on CO2 valorization and the state of the art, this work contributes to improving scientific understanding and optimizing these processes for sustainable CO2 management, as well as addressing challenges in high-pressure CO2 valorization that are crucial for industrial scaling-up. This includes the development of cost-effective and robust reactor materials and the development of low-cost catalysts that yield improved selectivity and long-term stability under realistic working environments.

Gold and Ceria Modified NiAl Hydrotalcite Materials as Catalyst Precursors for Dry Reforming of Methane

Structured hydrotalcite NiAl-HT material with Ni/Al atomic ratio of 2.5 was prepared by co-precipitation of Ni and Al nitrate precursors and then modified by the addition of 1 wt% Ce and/or 3 wt% Au species. The obtained materials, after calcination at 600 °C, were characterized by XRD, XPS and TPR. Their catalytic performance was tested through dry reforming of methane (DRM) and by the temperature-programmed surface reaction of methane (TPSR-CH4). Thermal gravimetry analysis (TGA) of the spent catalysts was performed to determine the amount of carbon accumulated during the reaction. The effects of the addition of cerium as a support promoter and gold as nickel promoter and the sequential addition of cerium and gold on the structural properties and on the catalytic efficiency were investigated. Under the severe condition of high space velocity (600,000 mL g−1 h−1), all the catalysts were quite active, with values of CH4 conversion between 67% and 74% at 700 °C. In particular, the combination of cerium and gold enhanced the CH4 conversion up to 74%. Both additives, individually and simultaneously, enhanced the nickel dispersion with respect to the unpromoted NiAl and favored the reducibility of the nickel. During DRM all the catalysts formed graphitic carbon, contributing to their deactivation. The lower carbon gasification temperature of the promoted catalysts confirmed a positive effect played by Ce and Au in assisting the formation of an easier-to-remove carbon. The positive effect was testified by the better stability of the Ce/NiAl with respect to the other catalysts. In the gold-containing samples, this effect was neutralized by Au diffusing towards the catalyst surface during DRM, masking the nickel active sites. TPSR-CH4 test highlighted different CH4 activation capability of the catalysts. Furthermore, the comparison of the deposited carbon features (amount and removal temperature) of the DRM and TPSR spent catalysts indicated a superior activation of CO2 by the Au/Ce/NiAl, to be related to the close interaction of gold and ceria enhancing the oxygen mobility in the catalyst lattice.

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.

Does CO2 Oxidize Ni Catalysts? A Quick X-ray Absorption Spectroscopy Answer

MgAl₂O₄-supported Ni materials are highly active and cost-effective CO₂ conversion catalysts, yet their oxidation by CO₂ remains dubious. Herein, NiO/MgAl₂O₄, prepared via colloidal synthesis (10 wt % Ni) to limit size distribution, or wet impregnation (5, 10, 20, and 40 wt % Ni), and bare, i.e., unsupported, NiO are examined in H₂ reduction and CO₂ oxidation, using thermal conductivity detector-based measurements and in situ quick X-ray absorption spectroscopy, analyzed via multivariate curve resolution-alternating least-squares. Ni reoxidation does not occur for bare Ni but is observed solely on supported materials. Only samples with the smallest particle sizes get fully reoxidized. The Ni-MgAl₂O₄ interface, exhibiting metal-support interactions, activates CO₂ and channels oxygen into the reduced lattice. Oxygen diffuses inward, away from the interface, oxidizing Ni entirely or partially, depending on the particle size in the applied oxidation time frame. This work provides evidence for Ni oxidation by CO₂ and explores the conditions of its occurrence and the importance of metal-support effects.

Dry Reforming of Methane on Ni/Nanorod-CeO2 Catalysts Prepared by One-Pot Hydrothermal Synthesis: The Effect of Ni Content on Structure, Activity, and Stability

The nanorod morphology of the CeO2 support has been recognized as more beneficial than other morphologies for catalytic activity in the dry reforming of methane. Ni/nanorod-CeO2 catalysts with different Ni contents were prepared by one-pot hydrothermal synthesis. Samples were characterized by X-ray diffraction (XRD), H2-temperature-programmed reduction (H2-TPR), H2-temperature-programmed desorption (H2-TPD), field emission scanning electron microscopy/energy dispersive spectroscopy (FE-SEM/EDS), Brunauer–Emmet–Teller (BET) and Barrett–Joyner–Halenda (BHJ) analysis. The effect of Ni content on the size and the intrinsic strain of ceria was analyzed by the Size–Strain plot and Williamson–Hall plot of XRD data. The average Ni particle size and Ni dispersion were determined by H2-TPD. XRD and H2-TPR analysis revealed a strong Ni–support interaction that limited nickel sintering. The activity for the dry reforming of methane was tested with the stoichiometric mixture CO2:CH4:N2:He = 20:20:20:140, gas hourly space velocity (GHSV) = 300 L g−1 h−1, and temperatures in the range of 545–800 °C. The turnover frequency (TOF) value increased linearly with the average Ni particle size in the range of 5.5–33 nm, suggesting the structure sensitivity of the reaction. Samples with Ni loading of 4–12 wt.% showed high H2/CO selectivity and stability over time on stream, whereas the sample with a Ni loading of 2 wt.% was less selective and underwent rapid deactivation. Only a small amount of nanotubular carbon was observed by FE-SEM after the time-on-stream experiment. Deactivation of the low-Ni-content sample is ascribed to the easier oxidation of the small Ni particles.

Performance Analysis of TiO2-Modified Co/MgAl2O4 Catalyst for Dry Reforming of Methane in a Fixed Bed Reactor for Syngas (H2, CO) Production

Co/TiO2–MgAl2O4 was investigated in a fixed bed reactor for the dry reforming of methane (DRM) process. Co/TiO2–MgAl2O4 was prepared by modified co-precipitation, followed by the hydrothermal method. The active metal Co was loaded via the wetness impregnation method. The prepared catalyst was characterized by XRD, SEM, TGA, and FTIR. The performance of Co/TiO2–MgAl2O4 for the DRM process was investigated in a reactor with a temperature of 750 °C, a feed ratio (CO2/CH4) of 1, a catalyst loading of 0.5 g, and a feed flow rate of 20 mL min−1. The effect of support interaction with metal and the composite were studied for catalytic activity, the composite showing significantly improved results. Moreover, among the tested Co loadings, 5 wt% Co over the TiO2–MgAl2O4 composite shows the best catalytic performance. The 5%Co/TiO2–MgAl2O4 improved the CH4 and CO2 conversion by up to 70% and 80%, respectively, while the selectivity of H2 and CO improved to 43% and 46.5%, respectively. The achieved H2/CO ratio of 0.9 was due to the excess amount of CO produced because of the higher conversion rate of CO2 and the surface carbon reaction with oxygen species. Furthermore, in a time on stream (TOS) test, the catalyst exhibited 75 h of stability with significant catalytic activity. Catalyst potential lies in catalyst stability and performance results, thus encouraging the further investigation and use of the catalyst for the long-run DRM process.

Dry Reforming of Methane over Carbon Fibre-Supported CeZrO2, Ni-CeZrO2, Pt-CeZrO2 and Pt-Ni-CeZrO2 Catalysts

Dry reforming of methane (DRM) is one of the most important processes allowing transformation of two most potent greenhouse gases into a synthesis gas. The CH4 and CO2 are converted at high temperatures in the presence of a metal catalyst (usually Ni, also promoted with noble metals, supported over various oxides). The DRM process is not widely used in the gas processing industry because of prompt deactivation of the catalyst owing to carbon deposition and the blockage of the metal active sites. This problem can be hindered by proper design of the catalyst in terms, e.g., of its composition and by providing strong interaction between active metal and catalytic support. The properties of the latter are also crucial for the catalyst’s performance in DRM and the occurrence of parallel reactions such as reverse water gas shift, CO2 deoxidation or carbon formation. In this paper we show for the first time the DRM performance of the ceria-zirconia and metal (Ni and/or Pt) supported on carbon fibres. The obtained Ni and Ni-Pt containing catalysts showed relatively high activity in the studied reaction and high resistance towards carbon deposition.

Nanowire-Based Materials as Coke-Resistant Catalyst Supports for Dry Methane Reforming

In this paper, nanowire-supported catalysts loaded with nickel are shown to be coke resistant compared to nanoparticle-supported catalysts. Specifically, Ni-loaded titania-based nanowire catalysts were tested with the dry methane reforming process in a laboratory-scale continuous packed-bed atmospheric reactor. The CO2 conversion rate stayed above 90% for over 30 h on stream under coke-promoting conditions, such as high flow rates, low temperatures, and a high ratio of CH4 to CO2. The coke (CxHy, x>>y) on the spent catalyst surface for both nanowire- and nanoparticle-supported catalysts was characterized by TGA, temperature-programmed reduction (TPR), and electron microscopy (SEM/TEM/EDS), and it was revealed that the types of carbon species present and their distribution over the morphology-enhanced materials played a major role in the deactivation. The CO2 conversion activity of Ni supported on titania nanoparticles was reduced from ~80% to less than 72% in 30 h due to the formation of a graphitic coke formation. On the other hand, Ni particles supported on nanowires exhibited cube-octahedral morphologies, with a high density of non- (111) surface sites responsible for the increased activity and reduced graphitic coke deposition, giving a sustained and stable catalytic activity during a long time-on-stream experiment.

Co3O4-Impregnated NiO-YSZ: An Efficient Catalyst for Direct Methane Electrooxidation

Co₃O₄-impregnated NiO-YSZ (yttria-stabilized zirconia) is a possible electrocatalyst for direct methane electrooxidation with both high catalytic activity and the ability to mitigate coking. The physical and electrochemical properties of Co₃O₄-impregnated NiO-YSZ anodes are investigated and benchmarked against NiO-YSZ and CeO₂-impregnated NiO-YSZ anodes. The following methane electrooxidation activity trend: Co₃O₄-impregnated NiO-YSZ > CeO₂-impregnated NiO-YSZ > NiO-YSZ with i_o (exchange current density) values of 88, 83, and 2 mA cm^-2, respectively, is obtained in the high overpotential region. The high activity of Co₃O₄-impregnated NiO-YSZ is attributed to the changes in the electronic structure and microstructure with the incorporation of nickel into the lattice of Co₃O₄ as observed using X-ray photoelectron spectroscopy, temperature-programmed reduction, high-resolution transmission electron microscopy, and field emission scanning electron microscopy. Co₃O₄-impregnated NiO-YSZ also demonstrated the least coking during operation, confirming its utility as a methane electrooxidation catalyst.

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.

Atomic order, electronic structure and thermodynamic stability of nickel aluminate

The atomic order, electronic structure and thermodynamic stability of nickel aluminate, NiAl2O4, have been analyzed using periodic density functional theory and cluster expansion. NiAl2O4 forms a tetragonal structure with P4122 space group. At temperatures below 800 K, it is an inverse spinel, with Ni occupying the octahedral sites and Al occupying both the octahedral and the tetrahedral sites. Some Niocta + Altetra ⇌ Nitetra + Alocta exchange occurs above 800 K, but the structure remains largely inverse at high temperatures, with about 95% Niocta at 1500 K. Various functionals, with and without van der Waals corrections, were used to predict the experimental formation energy, lattice parameters and electronic structure. In all cases, the NiAl2O4 is found to be ferromagnetic and a semiconductor with an indirect band gap along the Γ → M symmetry points. NiAl2O4 is found to be thermodynamically stable at operating conditions of 900-1000 K and 1 atm relative to its competing oxide phases, NiO and Al2O3.

Atomic Layer Deposition for Preparation of Highly Efficient Catalysts for Dry Reforming of Methane

In this article, the structural and chemical properties of heterogeneous catalysts prepared by atomic layer deposition (ALD) are discussed. Oxide shells can be deposited on metal particles, forming shell/core type catalysts, while metal nanoparticles are incorporated into the deep inner parts of mesoporous supporting materials using ALD. Both structures were used as catalysts for the dry reforming of methane (DRM) reaction, which converts CO2 and CH4 into CO and H2. These ALD-prepared catalysts are not only highly initially active for the DRM reaction but are also stable for long-term operation. The origins of the high catalytic activity and stability of the ALD-prepared catalysts are thoroughly discussed.

Ce- and Y-Modified Double-Layered Hydroxides as Catalysts for Dry Reforming of Methane: On the Effect of Yttrium Promotion

Ce- and Y-promoted double-layered hydroxides were synthesized and tested in dry reforming of methane (CH4/CO2 = 1/1). The characterization of the catalysts was performed using X-ray fluorescence (XRF), X-ray diffraction (XRD), N2 sorption, temperature-programmed reduction in H2 (TPR-H2), temperature-programmed desorption of CO2 (TPD-CO2), H2 chemisorption, thermogravimetric analysis coupled by mass spectrometry (TGA/MS), Raman, and high-resolution transmission electron microscopy (HRTEM). The promotion with cerium influences textural properties, improves the Ni dispersion, decreases the number of total basic sites, and increases the reduction temperature of nickel species. After promotion with yttrium, the increase in basicity is not directly correlated with the increasing Y loading on the contrary of Ni dispersion. Dry reforming of methane (DRM) was performed as a function of temperature and in isothermal conditions at 700 °C for 5 h. For catalytic tests, a slight increase of the activity is observed for both Y and Ce doped catalysts. This improvement can of course be explained by Ni dispersion, which was found higher for both Y and Ce promoted catalysts. During DRM, the H2/CO ratio was found below unity, which can be explained by side reactions occurrence. These side reactions are linked with the increase of CO2 conversion and led to carbon deposition. By HRTEM, only multi-walled and helical-shaped carbon nanotubes were identified on Y and Ce promoted catalysts. Finally, from Raman spectroscopy, it was found that on Y and Ce promoted catalysts, the formed C is less graphitic as compared to only Ce-based catalyst.

Advantages of Yolk Shell Catalysts for the DRM: A Comparison of Ni/ZnO@SiO2 vs. Ni/CeO2 and Ni/Al2O3

Encapsulation of metal nanoparticles is a leading technique used to inhibit the main deactivation mechanisms in dry reforming of methane reaction (DRM): Carbon formation and Sintering. Ni catalysts (15%) supported on alumina (Al2O3) and ceria (CeO2) have shown they are no exception to this analysis. The alumina supported catalysts experienced graphitic carbonaceous deposits, whilst the ceria showed considerable sintering over 15 h of DRM reaction. The effect of encapsulation compared to that of the performance of uncoated catalysts for DRM reaction has been examined at different temperatures, before conducting longer stability tests. The encapsulation of Ni/ZnO cores in silica (SiO2) leads to advantageous conversion of both CO2 and CH4 at high temperatures compared to its uncoated alternatives. This work showcases the significance of the encapsulation process and its overall effects on the catalytic performance in chemical CO2 recycling via DRM.

Low Temperature Activation of Carbon Dioxide by Ammonia in Methane Dry Reforming—A Thermodynamic Study

Methane dry reforming (MDR) is an attractive alternative to methane steam reforming for hydrogen production with low harmful environmental emissions on account of utilizing carbon dioxide in the feed. However, carbon formation in the product stream has been the most challenging aspect of MDR, as it leads to catalyst deactivation by coking, prevalent in hydrocarbon reforming reactions. Common strategies to limit coking have mainly targeted catalyst modifications, such as by doping with rare earth metals, supporting on refractory oxides, adding oxygen/steam in the feed, or operating at reaction conditions (e.g., higher temperature), where carbon formation is thermodynamically restrained. These methods do help in suppressing carbon formation; nonetheless, to a large extent, catalyst activity and product selectivity are also adversely affected. In this study, the effect of ammonia addition in MDR feed on carbon suppression is presented. Based on a thermodynamic equilibrium analysis, the most significant observation of ammonia addition is towards low temperature carbon dioxide activation to methane, along with carbon removal. Results indicate that ammonia not only helps in removing carbon formation, but also greatly enriches hydrogen production.