Effects of calcination and activation temperature on dry reforming catalysts

The effect of calcination temperatures on dry reforming catalysts supported on high surface area alumina Ni/γ-Al₂O₃ (SA-6175) was studied experimentally. In this study, the prepared catalyst was tested in a micro tubular reactor using temperature ranges of 500, 600, 700 and 800 °C at atmospheric pressure, using a total flow rate of 33 ml/min consisting of 3 ml/min of N₂, 15 ml/min of CO₂ and 15 ml/min of CH₄. The calcination was carried out in the range of 500–900 °C. The catalyst is activated inside the reactor at 500–800 °C using hydrogen gas. It was observed that calcination enhances catalyst activity which increases as calcination and reaction temperatures were increased. The highest conversion was obtained at 800 °C reaction temperature by using catalyst calcined at 900 °C and activation at 700 °C. The catalyst characterization conducted supported the observed experimental results.     

Performance of a mixed-conducting ceramic membrane reactor with high oxygen permeability for methane conversion

A mixed-conducting perovskite-type Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCFO) ceramic membrane reactor with high oxygen permeability was applied for the activation of methane. The membrane reactor has intrinsic catalytic activities for methane conversion to ethane and ethylene. C₂ selectivity up to 40–70% was achieved, albeit that conversion rate were low, typically 0.5–3.5% at 800–900°C with a 50% helium diluted methane inlet stream at a flow rate of 34 ml/min. Large amount of unreacted molecular oxygen was detected in the eluted gas and the oxygen permeation flux improved only slightly compared with that under non-reactive air/He experiments. The partial oxidation of methane to syngas in a BSCFO membrane reactor was also performed by packing LiLaNiO/γ-Al₂O₃ with 10% Ni loading as the catalyst. At the initial stage, oxygen permeation flux, methane conversion and CO selectivity were closely related with the state of the catalyst. Less than 21 h was needed for the oxygen permeation flux to reach its steady state. 98.5% CH₄ conversion, 93.0% CO selectivity and 10.45 ml/cm² min oxygen permeation flux were achieved under steady state at 850°C. Methane conversion and oxygen permeation flux increased with increasing temperature. No fracture of the membrane reactor was observed during syngas production. However, H₂-TPR investigation demonstrated that the BSCFO was unstable under reducing atmosphere, yet the material was found to have excellent phase reversibility. A membrane reactor made from BSCFO was successfully operated for the POM reaction at 875°C for more than 500 h without failure, with a stable oxygen permeation flux of about 11.5 ml/cm² min.     

Iron Oxide Supported on Al2O3 Catalyst for Methane Decomposition Reaction: Effect of MgO Additive and Calcination Temperature

Production of hydrogen is a challenging task and have significant impact in the recent scenario. The alumina supported iron oxide nanoparticle synthesized using non‐ionic surfactant Triton‐X was found very effective for steady production of hydrogen through methane decomposition reaction. The high surface area, easily reducible catalyst calcined at 500 °C and 800 °C temperature showed steady activity towards methane decomposition reaction. At a higher reaction temperature there was catalyst deactivation. The doping of MgO facilitated particle growth rendering the poor catalytic activity. The TPR study showed that reducibility of TPR was difficult in presence of MgO additive. The formation of Fe? Mg? Al solid solution confirmed by XRD study was found mainly responsible for the lower catalytic activity. The bamboo‐shaped carbon nanotube formed from 20 % Fe/Al₂O₃ catalyst which is mainly because of the poor wetting property of quasi‐liquid metal and carbon nanotube.     

Hydrogen production over partial oxidation of methane using NiMgAl spinel catalysts: A kinetic approach

NiMgAl–based catalysts were synthesized by coprecipitation, sol–gel, and impregnation methods, calcined at 700 °C for 4 h and tested in partial oxidation of methane in a temperature range of 500–800 °C. The fresh and used unsupported and supported samples were characterized by X-ray diffraction, nitrogen physisorption with Brunauer-Emett-Teller (BET) analysis, and H₂–temperature-programmed reduction. X-ray diffraction analysis showed, for all samples, the formation of spinel phases MgAl₂O₄ and/or NiAl₂O₄ with crystallite sizes of 6–14 nm. H₂–temperature-programmed reduction analysis showed reduction of two Ni²⁺ species (in octahedral and tetrahedral sites of a spinel structure) into metallic nickel known to be responsible for the methane activation. The 10 wt % Ni/MgAl₂O₄ impregnated catalysts exhibited the highest activity and stability in the partial oxidation of methane reaction, which led mainly to syngas (CO + H₂) at 800 °C with a methane conversion close to the thermodynamic equilibrium (95%). A kinetic model revealed that the oxidation of methane occurs on a thin layer of the catalytic bed in which oxygen is consumed and is followed by the production of CO and H₂ by methane steam reforming and water gas shift reactions.     

Carbon deposits on a resistive FeCrAl catalyst for the suboxidative pyrolysis of methane

The carbon deposits forming upon the suboxidative pyrolysis of methane on resistive FeCrAl catalysts heated with electric current were studied. The suboxidative pyrolysis of methane was carried out in a flow reactor at the ratio CH₄: O₂ = 15: 1 in a catalyst-coil temperature range of 600–1200°C; a cold reaction mixture (～20°C) was supplied. The morphology and structure of the carbon deposits and changes in the composition and structure of the catalyst were characterized by scanning electron microscopy, transmission electron microscopy with EDX analysis, Raman spectroscopy, and X-ray diffraction analysis. Various forms of carbon deposits, including branched nanotubes, and metal carbides formed by catalyst constituents were detected. It was found that the carbon deposits on the catalyst surface were morphologically different from the deposits on quartz reactor walls. The reasons for these differences were considered.     

Catalytic oxidation of methane over Pd/Co3O4

The catalytic activity of Pd/Co₃O₄ toward methane oxidation has been examined in this study as a function of Pd loading, reaction temperature, space velocity and methane concentration in the reaction gas mixture. The bare oxide is quite active achieving a 100% methane conversion at 480°C under the reaction conditions used. The catalyst with the highest Pd loading tested of 10 wt.% yields the best activity curve, but the 5 wt.% Pd/Co₃O₄ catalyst performs nearly as well. Complete conversion for this catalyst is attained at 300°C and the activity remains stable over a 90-min test period.     

Comparative study of the synthesis of CoFe<Subscript>2</Subscript>O<Subscript>4</Subscript> and NiFe<Subscript>2</Subscript>O<Subscript>4</Subscript> in silica through the polymerized complex route of the sol–gel method

In this work the synthesis of CoFe₂O₄-SiO₂ and NiFe₂O₄-SiO₂ nanocomposites was studied via the sol–gel method, using the polymerized complex route. The polymerized precursors obtained by the reaction of citric acid, ethylene glycol, tetraethylorthosilicate, ferric nitrate, and cobalt nitrate or nickel chloride were characterized by nuclear magnetic resonance (NMR) and infrared (IR) spectroscopy. NMR and IR spectra of the precursors, without and with metallic ions, show the formation of polymeric chains with ester and ether groups and complexes of metal-polymeric precursor. The nanocomposites were obtained by the thermal decomposition of the organic fraction and characterized by X-ray diffraction (XRD) and vibrating sample magnetometry (VSM). XRD patterns show the formation of CoFe₂O₄ and NiFe₂O₄ in an amorphous silica matrix above 400 °C in both cases. When the calcination temperature was 800 °C the particle size of the crystalline phases, calculated using the Scherrer equation, reached ∼35 nm for the two oxides. VSM plots show the ferrimagnetic behavior that is expected for this type of magnetic material; the magnetization at 12.5 KOe of the CoFe₂O₄-SiO₂ and NiFe₂O₄-SiO₂ compounds was 29.5 and 17.4 emu/g, respectively, for samples treated at 800 °C.     

The oxidative stream reforming of methane to syngas in a thin tubular mixed-conducting membrane reactor

The oxidative stream reforming of methane (OSRM) to syngas, involving coupling of exothermic partial oxidation of methane (POM) and endothermic steam reforming of methane (SRM) processes, was studied in a thin tubular Al₂O₃-doped SrCo_0.8Fe_0.2O_3−δ membrane reactor packed with a Ni/γ-Al₂O₃ catalyst. The influences of the temperature and feed concentration on the membrane reaction performances were investigated in detail. The methane and steam conversions increased with increasing the temperature and high conversions were obtained in 850–900 °C. Different from the POM reaction, in the OSRM reaction the temperature and H₂O/CH₄ profoundly influenced the CO selectivity, H₂/CO and heat of the reaction. The CO selectivity increased with increasing the temperature or decreasing the H₂O/CH₄ ratio in the feed owing to the water gas shift reaction (H₂O + CO → CO₂ + H₂). And the H₂ selectivity based on methane conversion was always 100% because the net steam conversion was greater than zero. The H₂/CO in product could be tuned from 1.9 to 2.8 by adjusting the reaction temperature or H₂O/CH₄. Depending on the temperature or H₂O/CH₄, furthermore, the OSRM process could be performed auto-thermally with idealized reaction condition.     

High performance cathode-supported SOFC with perovskite anode operating in weakly humidified hydrogen and methane

A high performance cathode-supported solid oxide fuel cell (SOFC), suitable for operating in weakly humidified hydrogen and methane, has been developed. The SOFC is essentially made up by a YSZ/LSM composite supporting cathode, a thin YSZ film electrolyte, and a GDC-impregnated La_0.75Sr_0.25Cr_0.5Mn_0.5O₃ (LSCM) anode. A gas tight thin YSZ film (∼27 μm) was formed during the co-sintering of cathode/electrolyte bi-layer at 1200 °C. The cathode-supported SOFC developed in this study showed encouraging performance with maximum power density of 0.182, 0.419, 0.628 and 0.818 W cm⁻² in air/3% H₂O–97% H₂ (and 0.06, 0.158, 0.221 and 0.352 W cm⁻² in air/3% H₂O–97% CH₄) at 750, 800, 850 and 900 °C, respectively. Such performance is close to that of the cathode-supported cell (0.42 W cm⁻² vs. 0.455 W cm⁻² in humidified H₂ at 800 °C) developed by Yamahara et al. [Solid State Ionics 176 (2005) 451–456] with a Co-infiltrated supporting LSM-YSZ cathode, a (Sc₂O₃)_0.1(Y₂O₃)_0.01(ZrO₂)_0.89 (SYSZ) electrolyte of 15 μm in thickness and a SYSZ/Ni anode, indicating that the performance of the GDC-impregnated LSCM anode is comparable to that made of Ni cermet while stable in weakly humidified methane fuel.     

Cobalt promoted Ni/MgAl2O4 catalyst in lean methane catalytic oxidation

In the present research, magnesium aluminate spinel was prepared as catalyst support using a novel, facile, and efficient mechanochemical method. The Co-promoted catalysts with 20 wt.% of Ni were fabricated using an impregnation route and the samples were analyzed by the X-ray diffraction (XRD), N₂ adsorption/desorption (BET), temperature-programmed reduction and desorption (H₂-TPR and O₂-TPD), and field emission scanning electron microscopy (FESEM) tests. The results confirmed that all samples have a mesoporous structure with a high specific surface area and the presence of cobalt caused complete CH₄ oxidation at low temperatures, and no side reactions were observed. The results indicated that the 3%Co-20%Ni/MgAl₂O₄ catalyst was the optimal sample among the prepared catalysts, owing to the improvement of reduction features and oxygen mobility. The 50 and 90% of methane conversion was obtained at 530 and 600 °C, respectively. Also, the influence of calcination temperature, GHSV, and feed ratio was determined on the catalytic activity. The obtained outcomes revealed that the calcination temperature has a significant effect on the textural properties and catalytic efficiency. The sample calcined at 700 °C showed the weakest performance, which was related to the sintering of particles at high temperatures. The catalytic stability showed that the 3%Co-20%Ni/MgAl₂O₄ has acceptable stability during 600 min time of reaction.

Graphical abstract

     

Characterization of LaRhO3 perovskites for dry (CO2) reforming of methane (DRM)

This work reports on the characterization of LaRhO₃ perovskite as a catalyst for dry reforming of methane. The catalyst was studied using CH₄-temperature programmed reduction (TPR), H₂-TPR, and temperature programmed surface reaction (TPSR), and the changes in the crystal structure of the catalyst due to these treatments were studied by X-ray diffraction (XRD). XRD pattern of the freshly calcined perovskites showed the formation of highly crystalline LaRhO₃ and La₂O₃ phases. H₂-TPR of the fresh calcined catalyst showed a shoulder at 342°C and a broad peak at 448°C, suggesting that the reduction of Rh in perovskite occurs in multiple steps. XRD pattern of the reduced catalyst suggests complete reduction of the LaRhO₃ phase and the formation of metallic Rh and minor amounts of La(OH)₃. The CH4-TPR data show qualitatively similar results as H₂-TPR, with a shoulder and a broad peak in the same temperature range. Following the H₂-TPR up to 950°C, the same batch of catalyst was oxidized by flowing 5 vol. % O₂/He up to 500°C and a second H₂-TPR (also up to 950°C) was conducted. This second H₂-TPR differed significantly from that of the fresh calcined catalyst. The single sharp peak at 163°C in the second H₂-TPR suggests a significant change in the catalyst, probably causedby the transformation of about 90 % of the perovskite into Rh/La₂O₃. This was confirmed by the XRD studies of the catalyst reduced after the oxidation at 500°C. TPSR of the dry reforming reaction on the fresh calcined catalyst showed CO and H₂ formation starting at 400°C, with complete consumption of the reactants at 650°C. The uneven consumption of reactants between 400°C and 650°C suggests that reactions other than DRM occur, including reverse water gas shift (RWGS) and the Boudouard reaction (BR), probably as a result of in-situ changes in the catalyst, consistent with the H₂-TPR results. TPSR, after a H₂-TPR up to 950°C, showed that the dry reforming reaction did not light off until 570°C, which is much higher temperature than the one observed using fresh calcined catalyst. This shows that the uniform sites produced during the 950°C H₂-TPR are catalytically less active than those of the fresh calcined catalyst, and that no significant side reactions such as RWGS or the Boudouard reaction occur. This suggests that reduction leads to the formation of a single type of sites which do not catalyze simultaneous side reactions.     

A novel approach for synthesis of nanocrystalline γ-LiAlO2 from spent lithium-ion batteries

Synthesis of nanocrystallite γ-LiAlO₂ from spent lithium-ion batteries has been investigated. XRD results show that γ-LiAlO₂ phase can be synthesized by thermal treatment of the cathode material over its aluminum sheet at 800–900 °C for 2 h. This is accompanied with the formation of Co₃O₄ and CoO phases as colored powders. SEM investigation revealed the formation of dense grains as coconut-like shape structure of γ-LiAlO₂ phase. Comparatively, reaction of chemical grade Al powder with LiOH in stoichiometric ratio at 800 °C gives γ-LiAlO₂ phase of cotton-like morphology.     

Novel Ni/CeO2-Al2O3 composite catalysts synthesized by one-step citric acid complex and their performance in catalytic partial oxidation of methane

A series of novel Ni/CeO2-Al2O3composite catalysts were synthesized by one-step citric acid complex method. The as-synthesized catalysts were characterized by N2physical adsorption/desorption, X-ray diffraction(XRD), Fourier transform infrared(FT-IR) spectroscopy, hydrogen temperature-programmed reduction(H2-TPR), X-ray photoelectron spectroscopy(XPS) and thermogravimetry analysis(TGA). The effects of nickel content, calcination and reaction temperatures, gas hourly space velocity(GHSV) and inert gas dilution of N2on their performance of catalytic partial oxidation of methane(CPOM) were investigated. Catalytic activity test results show that the highest methane conversion(85%), the best selectivities to carbon monoxide(87%) and to hydrogen(95%), the excellent stability and perfect H2/CO ratio(2.0) can be obtained over Ni/CeO2-Al2O3with 8 wt% Ni content calcined at 700 ℃ under the reaction condition of 750 ℃, CH4/O2ratio of 2 : 1 and gas hourly space velocity of 12000 mL h-1 g-1. Characterization results show that the good catalytic performance of this composite catalyst can be contributed to its large specific surface area(～108 m2 g-1), small crystallite size, easy reducibility and low coking rate.     

The nature of the deposited carbon at methane cracking over a nickel loaded wood-char

The catalytic properties of raw biomass chars and Ni-loaded biomass chars prepared at a high-heating-rate were assessed in the methane decomposition reaction. The raw chars exhibited a moderated catalytic activity in methane cracking while the Ni-loaded chars showed a catalytic activity 10 times higher than the raw chars. The deposited carbon was a highly ordered one as evidenced by XRD, Raman analysis and oxygen reactivity tests. The activation energy in the combustion reaction was estimated to be 300 kJ/mol. These results indicate that biomass char can be an effective low-cost and active support for metal impregnation to be used in catalytic cracking of hydrocarbons for hydrogen production.     

Kinetic studies of the oxidative coupling of methane over the Mn/Na2WO4/SiO2 catalyst

Oxidative coupling of methane is a direct way to obtain C2 hydrocarbon,and Mn-Na-W/SiO2 catalyst is the most promising among all the catalysts.The 2%Mn/5%Na2WO4/SiO2 catalyst was prepared by the incipient wetness impregnation method.A 7-step heterogeneous reaction model of the oxidative coupling of methane to C2 hydrocarbons was conducted by co-feeding methane and oxygen at a total pressure of 1 bar over the catalyst.The kinetic measurements were carried out in a micro-catalytic fixed bed reactor.The kinetic data were obtained at the appropriate range of reaction conditions (4 kPa＜Po2 ＜20 kPa,20 kPa＜PCZH4 ＜80 kPa,800℃＜T＜900℃).The proposed reaction kinetic scheme consists of three primary and four consecutive reaction steps.The conversions of hydrocarbons and carbon oxides were evaluated by applying Langrnuir-Hinshelwood type rate equations.Power-law rate equation was applied only for the water-gas shift reaction.In addition,the effects of operating conditions on the reaction rate were studied.The proposed kinetic model can predict the conversion of methane and oxygen as well as the yield of C2 hydrocarbons and carbon oxides with an average accuracy of ±15%.     

Preparation and characterization of nanocrystalline CoFe<Subscript>2</Subscript>O<Subscript>4</Subscript> deposited on SiO<Subscript>2</Subscript>: in situ sol–gel process

In situ base catalyst assisted sol–gel process is used for the synthesis of nanocrystalline CoFe₂O₄ deposition on SiO₂ particles. The SiO₂ particles were prepared using base catalyst assisted sol–gel process and the consecutive formation and deposition of nanocrystalline CoFe₂O₄ on SiO₂ particles was monitored using Powder X ray Diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR), Thermo Gravimetric And Differential Thermal Analysis (TG/DTA), Scanning Electron Microscopy and Energy Dispersive X ray Spectroscopy (SEM–EDS) and High Resolution Transmission Electron Microscopy (HRTEM). The crystallite size of CoFe₂O₄ is calculated using Scherrer’s formula and it is found to be 8 nm. The HRTEM images and selective area electron diffraction (SAED) results confirmed the formation of nanocrystalline CoFe₂O₄ particles deposited over SiO₂ spheres.     

Sorption-enhanced steam methane reforming over Ni/Al2O3/KNaTiO3 bifunctional material

The performance of a new lab-made bifunctional material Ni/Al₂O₃/KNaTiO₃ for producing high purity H₂ via sorption-enhanced steam methane reforming (SESMR) was investigated. A series of bifunctional materials with 10 wt% Ni loading but different wt% ratios of KNaTiO₃ and Al₂O₃ was prepared by wetness impregnation method. All the materials were calcined at 700 °C for 3 hours and screened for their catalytic activity in a continuous flow fixed-bed reactor. The material containing 50 wt% each of KNaTiO₃ and Al₂O₃ (designated as HM) was found to be the best choice. The optimum process parameters for the production of high purity H₂ were determined: temperature = 700 °C, steam to carbon (S/C) molar ratio = 6 and gas-hourly space velocity (GHSV) = 2000 cm³ g^-1 h^-1. The values of CH₄ conversion, H₂ yield and H₂ purity were 87, 87 and 90%, respectively, at the optimum reaction conditions. The adsorption capacity of HM was found to be 14.7 wt%. With a breakthrough time of 10 min, the material was stable for 8 adsorption-desorption cycles. The regeneration of HM was achieved with N₂ gas at the same reaction temperature. Overall, the activity of this material for SESMR was very promising.     

Nonoxidative conversion of methane and <Emphasis Type="Italic">n</Emphasis>-pentane over a platinum/alumina catalyst

Methane adsorption on the Pt–H/Al₂O₃ and Pt/Al₂O₃ catalysts begins at Т = 475°C and is accompanied by the appearance of hydrogen in the reaction medium. At a higher temperature is raised to 550°C, the amount of adsorbed hydrogen increases to 1.1 and 0.8 mol/(mol Pt), respectively. According to the calculated degree of methane dehydrogenation on platinum sites at Т = 550°C, the Н/C ratio is 1.3 (at/at) for the Pt–H/Al₂O₃ catalyst and 1.5 (at/at) for the Pt/Al₂O₃ catalyst. The introduction of n-pentane into the reaction medium increases the yield of aromatic hydrocarbons (benzene and toluene) by a factor of 8.8 over the arene yield observed in individual n-pentane conversion. A mass spectrometric analysis of the arenes obtained with the Pt/Al₂O₃ catalyst has demonstrated that 37.5% of the adsorbed methane is involved in the methane–n-pentane coaromatization yielding benzene and toluene.     

Porous carbon as electrode material in direct ethanol fuel cells (DEFCs) synthesized by the direct carbonization of MOF-5

Porous carbon (PC-900) was prepared by direct carbonization of porous metal-organic framework (MOF)-5 (Zn₄O(bdc)₃, bdc?=?1,4-benzenedicarboxylate) at 900 °C. The carbon material was deposited with PtM (M?=?Fe, Ni, Co, and Cu (20 %) metal loading) nanoparticles using the polyol reduction method, and catalysts PtM/PC-900 were designed for direct ethanol fuel cells (DEFCs). However, herein, we are reporting PtFe/PC-900 catalyst combination which has exhibited superior performance among other options. This catalyst was characterized by powder XRD, high-resolution transmission electron microscopy (HRTEM), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), and selected area electron diffraction (SAED) technique. The electrocatalytic capability of the catalyst for ethanol electrooxidation was investigated using cyclic voltammetry and direct ethanol single cell testing. The results were compared with those of PtFe and Pt supported on Vulcan XC72 carbon catalysts (PFe/CX-72 and Pt/XC-72) prepared via the same method. It has been observed that the catalyst PtFe/PC-900 developed in this work showed an outstanding normalized activity per gram of Pt (6.8 mA/g Pt) and superior power density (121 mW/cm² at 90 °C) compared to commercially available carbon-supported catalysts.     

Influence of a Fe/activated carbon catalyst and reaction parameters on methane decomposition during the synthesis of carbon nanotubes

In our experimental work on carbon nanotubes synthesis, the influence of pre-treatment and reaction temperature conditions over Fe catalyst loaded on low-cost activated carbon (AC) in the catalytic chemical vapor deposition of methane was studied. Catalyst with the metal concentration of 5 mass % calcined at 350°C and reduced at 450°C was effective in CH₄ decomposition giving 98 % conversions. TEM images showed that thin multi-walled carbon nanotubes (MWNTs) with the average internal diameter of ∼ 8 nm and the wall thickness of ∼ 2.5 nm were obtained over unreduced Fe/AC catalyst at the reaction temperature of 850°C. On the other hand, broader filamentous nanostructures with the diameter of ∼ 22 nm and the wall thickness of ∼ 3.72 nm were observed over reduced catalyst.