The review of Cr-free Fe-based catalysts for high-temperature water-gas shift reactions

Insights from Modulation-Excitation Spectroscopy into the Role of Pt Geometrical Sites in the WGS Reaction

Modulation-excitation spectroscopy coupled to diffuse reflectance infrared Fourier transform spectroscopy (ME-DRIFTS) was explored in this work to obtain valuable insights into the structure-reactivity relations in nanostructured Pt catalysts for the water-gas shift (WGS) reaction. By using model Pt catalytic systems composed of colloidal Pt nanoparticles (NPs) deposited on CeO2 (i.e., reducible) and SiO2 (i.e., nonreducible) supports, it was possible to probe distinct Pt active sites and correlate them to the reaction intermediates and pathways. The analysis revealed that PtNPs/SiO2 favored the participation of well-coordinated (WC) and under-coordinated (UC) Pt sites in the reaction mechanism. In contrast, on PtNPs/CeO2/SiO2, the additional involvement of highly under-coordinated (HUC) Pt sites was also observed. Additionally, both fast and slow formate species were identified as active intermediates on the surface of the PtNPs/CeO2/SiO2 catalyst by ME-DRIFTS. More importantly, the faster reaction pathway was correlated to HUC and UC Pt sites, while the slower route was associated with WC Pt sites. Carbonates, on the other hand, were spectators. ME-DRIFTS experimentally demonstrate differences in the participation of Pt active sites according to the support, the involvement of interfacial sites, and the correlation of Pt local coordination to the surface intermediates in the WGS reaction.

Design of Cr-Free Promoted Copper-Iron Oxide-Based High-Temperature Water-Gas Shift Catalysts

The effect of Ce addition to the Cr-free Al-promoted Cu-Fe oxide-based catalysts is investigated. Catalyst characterization (X-ray diffraction (XRD), in situ Raman spectroscopy, high-sensitivity low-energy ion scattering (HS-LEIS), Brunauer-Emmett-Teller (BET) analysis), CO-temperature-programmed reduction chemical probing, and steady-state WGS activity reveal that (i) in the absence of Al, Ce addition via coprecipitation has a detrimental effect on the catalytic activity related to the poor thermostability and formation of less active Ce-Cu-O NPs, (ii) the addition of Ce via coprecipitation also does not improve the performance of the CuAlFe catalyst because of the formation of a thick CeOx overlayer on the active Cu-FeOx interface, and (iii) impregnation of Ce onto the CuAlFe catalyst exhibits significant improvement in catalytic performance due to the formation of a highly active CeOx-FeOx-Cu interfacial area. In summary, Al does not surface-segregate and serves as a structural promoter, while Ce and Cu surface-segregate and act as functional promoters in Ce/CuAlFe mixed oxide catalysts.

Hydrogen Production by Three-Stage (i) Pyrolysis, (ii) Catalytic Steam Reforming, and (iii) Water Gas Shift Processing of Waste Plastic

The three-stage (i) pyrolysis, (ii) catalytic steam reforming, and (iii) water gas shift processing of waste plastic for the production of hydrogen have been investigated. The (i) pyrolysis and (ii) catalytic steam reforming process conditions were maintained throughout, and the experimental program investigated the influence of process conditions in the (iii) water gas shift reactor in terms of catalyst type (metal-alumina), catalyst temperature, steam/carbon ratio, and catalyst support material. The metal-alumina catalysts investigated in the (iii) water gas shift stage showed distinct maximization of hydrogen yield, which was dependent on the catalyst type at either higher temperature (550 °C) (Fe/Al₂O₃, Zn/Al₂O₃, Mn/Al₂O₃) or lower temperature (350 °C) (Cu/Al₂O₃, Co/Al₂O₃). The highest hydrogen yield was found with the Fe/Al₂O₃ catalyst; also, increased catalyst Fe metal loading resulted in improved catalytic performance, with hydrogen yield increasing from 107 mmol g_plastic ^-1 at 5 wt % Fe loading to 122 mmol g_plastic ^-1 at 40 wt % Fe/Al₂O₃ Fe loading. Increased addition of steam to the (iii) water gas shift reactor in the presence of the Fe/Al₂O₃ catalyst resulted in higher hydrogen yield; however, as further steam was added, the hydrogen yield decreased due to catalyst saturation. The Fe-based catalyst support materials investigated alumina (Al₂O₃), dolomite, MCM-41, silica (SiO₂), and Y-zeolite; all showed similar hydrogen yields of ∼118 mmol g_plastic ^-1, except for the Fe/MCM-41 catalyst, which produced only 88 mmol g_plastic ^-1 of hydrogen yield.

Theoretical Calculations on Metal Catalysts Toward Water-Gas Shift Reaction: a Review

Water-gas shift (WGS) reaction offers a dominating path to hydrogen generation from fossil fuel, in which heterogeneous metal catalysts play a crucial part in this course. This review highlights and summarizes recent developments on theoretical calculations of metal catalysts developed to date, including surface structure (e. g., monometallic and polymetallic systems) and interface structure (e. g., supported catalysts and metal oxide composites), with special emphasis on the characteristics of crystal-face effect, alloying strategy, and metal-support interaction. A systematic summarization on reaction mechanism was performed, including redox mechanism, associative mechanism as well as hybrid mechanism; the development on chemical kinetics (e. g., molecular dynamics, kinetic Monte Carlo and microkinetic simulation) was then introduced. At the end, challenges associated with theoretical calculations on metal catalysts toward WGS reaction are discussed and some perspectives on the future advance of this field are provided.

Modification strategies of heterogeneous catalysts for water-gas shift reactions

Featured by high energy density, hydrogen has been deemed as a clean and renewable energy source compared with conventional fossil fuels. Water-gas shift reaction (WGSR) exhibits great potential in the...

Water Gas Shift Reaction Activity on Fe (110): A DFT Study

Metal Fe is one of the phases existing on iron-based catalysts for a high-temperature water gas shift reaction (WGSR), but research on the activity of metal Fe in WGSR is almost not reported. In this work, the density functional theory (DFT) method was used to systematically study the reaction activity and mechanisms of WGSR on metal Fe (110), including the dissociation of H2O, the transformation of CO and the formation of H2, as well as the analysis of surface electronic properties. The results show that (1) the direct dissociation of H2O occurs easily on Fe (110) and the energy barrier is less than 0.9 eV; (2) the generation of CO2 is difficult and its energy barrier is above 1.8 eV; (3) H migrates easily on the Fe surface and the formation of H2 also occurs with an energy barrier of 1.47 eV. Combined with the results of Fe3O4, it can be concluded that the active phase should be Fe3O4 with O vacancy defects, and the iron-rich region plays an important role in promoting the formation of H2 in WGSR.

Fabrication of More Oxygen Vacancies and Depression of Encapsulation for Superior Catalysis in the Water-Gas Shift Reaction

Fabrication of sufficient oxygen vacancies and exposure of active sites to reactants are two key factors to obtain high catalytic activity in the water-gas shift (WGS) reaction. However, these two factors are hard to satisfy spontaneously, since the formation of oxygen vacancies and encapsulation of metal nanoparticles are two inherent properties in reducible metal oxide supported catalysts due to the strong metal-support interaction (SMSI) effect. In this work, we find that addition of alkali to an anatase supported Ni catalyst (Ni/TiO₂(A)) could well regulate the SMSI to achieve both more oxygen vacancies and depression of encapsulation; therefore, more than 20-fold enhancement in activity is obtained. It is found that the in situ formed titanate species on the catalyst surface is crucial to the formation of oxygen vacancies and depression of encapsulation. Furthermore, the methanation, a common side reaction of the WGS reaction, is successfully suppressed in the whole catalytic process.

In Situ Study of Reduction of MnxCo3-xO4 Mixed Oxides: The Role of Manganese Content

A series of Mn-Co mixed oxides with a gradual variation of the Mn/Co molar ratio were prepared by coprecipitation of cobalt and manganese nitrates. The structure, chemistry, and reducibility of the oxides were studied by X-ray diffraction (XRD), X-ray absorption spectroscopy, X-ray photoelectron spectroscopy (XPS), and temperature-programmed reduction (TPR). It was found that at concentrations of Mn below 37 atom %, a solid solution with a cubic spinel structure is formed. At concentrations above 63 atom %, a solid solution is formed on the basis of a tetragonal spinel, while at concentrations in a range of 37-63 atom %, a two-phase system, which contains tetragonal and cubic oxides, is formed. To elucidate the reduction route of mixed oxides, two approaches were used. The first was based on a gradual change in the chemical composition of Mn-Co oxides, illustrating slow changes in the TPR profiles. The second approach consisted in a combination of in situ XRD and pseudo-in situ XPS techniques, which made it possible to directly determine the structure and chemistry of the oxides under reductive conditions. It was shown that the reduction of Mn-Co mixed oxides proceeds via two stages. During the first stage, (Mn, Co)₃O₄ is reduced to (Mn, Co)O. During the second stage, the solid solution (Mn, Co)O is transformed into metallic cobalt and MnO. The introduction of manganese cations into the structure of cobalt oxide leads to a decrease in the rate of both reduction stages. However, the influence of additional cations on the second reduction stage is more noticeable. This is due to crystallographic peculiarities of the compounds: the conversion from the initial oxide (Mn, Co)₃O₄ into the intermediate oxide (Mn, Co)O requires only a small displacement of cations, whereas the formation of metallic cobalt from (Mn, Co)O requires a rearrangement of the entire structure.

DFT insights into structural effects of Ni-Cu/CeO2 catalysts for CO selective reaction towards water-gas shift

The water-gas shift (WGS) reaction is a key step in hydrogen production, particularly to meet the high-purity H2 requirement of PEM fuel cells. The catalysts currently employed in large-scale WGS plants require a two-step process to overcome thermodynamic and kinetic limitations. Ni-Cu/CeO2 solids are promising catalysts for the one-step process required for small-scale applications, as the addition of Cu hinders undesired methanation reactions occurring on Ni/CeO2. In this work, we performed calculations on Ni4-xCux/CeO2(111) systems to evaluate the influence of cluster conformation on the selectivity towards water-gas shift. The structure and miscibility of CeO2-supported Ni4-xCux clusters were investigated and compared with those of gas-phase clusters to understand the effect of metal-support interactions. The adsorption of CO onto apical Ni and Cu atoms of Ni4-xCux/CeO2(111) systems was studied, and changes in the C-O bond strength were confirmed at the electronic level by investigating shifts in the 3σ and 1π orbitals. The selectivity towards WGS was evaluated using Brønsted-Evans-Polanyi relations for the C-O activation energy. Overall, a strengthening of the C-O bond and an increase in CO dissociation energy were verified on Cu-containing clusters, explaining the improvement in selectivity of Ni4-xCux/CeO2(111) systems.

Roles of highly ordered mesoporous structures of Fe–Ni bimetal oxides for an enhanced high-temperature water-gas shift reaction activity

Highly ordered mesoporous Fe–Ni bimetal oxide (m-FeNi) catalysts synthesized using KIT-6 as a hard-template by a nanocasting method were investigated for an alternative high-temperature water-gas shift (HT-WGS) reaction.

Reversible structural transformation and redox properties of Cr-loaded iron oxide dendrites studied by in situ XANES spectroscopy

Cr-Loaded iron oxide with a dendritic crystalline structure was synthesized and the reversible crystalline phase transition during redox cycling of the iron oxide was investigated. X-ray diffraction and transmission electron microscopy analyses revealed that Cr was well dispersed and loaded in the iron oxide dendrite crystals, whose lattice constant was dependent on the Cr loading. Temperature-programmed oxidation and reduction experiments revealed the reversible redox properties of the Cr-loaded iron oxide dendrites, whose redox temperature was found to be lower than that of Cr-free iron oxide dendrites. In situ Fe K-edge and Cr K-edge X-ray absorption near-edge structure (XANES) analysis indicated that Cr loading extended the redox reaction window for conversion between Fe3O4 and γ-Fe2O3 owing to compressive lattice strain in the iron oxide spinel structures.

FeCeOx Supported Ni, Sn Catalysts for the High-Temperature Water–Gas Shift Reaction

In this work, the effect of monometallic Ni or Sn and bimetallic NiSn deposition on the activity of FeCeOx catalysts in high-temperature water–gas (HT-WGS) reactions was investigated. It was found that the HT-WGS performance of FeCeOx has significantly improved after the deposition of Sn together with Ni on it. Furthermore, the bimetallic NiSn/FeCeOx catalyst showed higher activity compared to the monometallic Ni/FeCeOx and Sn/FeCeOx catalysts within the tested temperature range (450–600 °C). Although the Ni/FeCeOx catalyst showed methanation activity at a temperature below 550 °C, the NiSn/FeCeOx catalyst suppressed the methane formation to zero in the WGS. Besides, the NiSn/FeCeOx catalyst exhibited an excellent time-on-stream stability without methanation reaction, even at a steam-to-CO ratio as low as 0.8. The combination of Ni and Sn supported on FeCeOx led to a large lattice strain, the formation of NiSn alloy, and a strong synergistic effect between the bimetallic NiSn and FeCeOx mixed oxide support interface. All these features are very important in achieving the best activity and stability of NiSn/FeCeOx in the HT-WGS reaction.

High Temperature Water Gas Shift Reactivity of Novel Perovskite Catalysts

High temperature water-gas shift (HT-WGS) is an industrially highly relevant reaction. Moreover, climate change and the resulting necessary search for sustainable energy sources are making WGS and reverse-WGS catalytic key reactions for synthetic fuel production. Hence, extensive research has been done to develop improved or novel catalysts. An extremely promising material class for novel highly active HT-WGS catalysts with superior thermal stability are perovskite-type oxides. With their large compositional flexibility, they enable new options for rational catalyst design. Particularly, both cation sites (A and B in ABO3) can be doped with promoters or catalytically active elements. Additionally, B-site dopants are able to migrate to the surface under reducing conditions (a process called exsolution), forming catalytically active nanoparticles and creating an interface that can strongly boost catalytic performance. In this study, we varied A-site composition and B-site doping (Ni, Co), thus comparing six novel perovskites and testing them for their HT-WGS activity: La0.9Ca0.1FeO3-δ, La0.6Ca0.4FeO3-δ, Nd0.9Ca0.1FeO3-δ, Nd0.6Ca0.4FeO3-δ, Nd0.6Ca0.4Fe0.9Ni0.1O3-δ and Nd0.6Ca0.4Fe0.9Co0.1O3-δ. Cobalt and Nickel doping resulted in the highest activity observed in our study, highlighting that doped perovskites are promising novel HT-WGS catalysts. The effect of the compositional variations is discussed considering the kinetics of the two partial reactions of WGS-CO oxidation and water splitting.

Pt/Re/CeO2 Based Catalysts for CO-Water–Gas Shift Reaction: from Powders to Structured Catalyst

This work focuses on the development of a Pt/Re/CeO2-based structured catalyst for a single stage water–gas shift process. In the first part of the work, the activity in water–gas shift reactions was evaluated for three Pt/Re/CeO2-based powder catalysts, with Pt/Re ratio equal to 1/1, 1/2 ad 2/1 and total loading ≈ 1 wt%. The catalysts were prepared by sequential dry impregnation of commercial ceria, with the salts precursors of rhenium and platinum; the activity tests were carried out by feeding a reacting mixture with a variable CO/H2O ratio, equal to 7/14, 7/20 and 7/24, and the kinetic parameters were determined. The model which better described the experimental results involves the water–gas shift (WGS) reaction and CO as well as CO2 methanation. The preliminary tests showed that the catalyst with the Pt/Re ratio equal to 2/1 had the best performance, and this was selected for further investigations. In the second part of the work, a structured catalyst, obtained by coating a commercial aluminum alloy foam with the chosen catalytic formulation, was prepared and tested in different reaction conditions. The results demonstrated that a single stage water–gas shift process is achievable, obtaining a hydrogen production rate of 18.7 mmol/min at 685 K, at τ = 53 ms, by feeding a simulated reformate gas mixture (37.61 vol% H2, 9.31 vol% CO2, 9.31 vol% CO, 42.19 vol% H2O, 1.37 vol% CH4).

Efficient Waste to Energy Conversion Based on Co-CeO2 Catalyzed Water-Gas Shift Reaction

Waste to energy technology is attracting attention to overcome the upcoming environmental and energy issues. One of the key-steps is the water-gas shift (WGS) reaction, which can convert the waste-derived synthesis gas (H2 and CO) to pure hydrogen. Co–CeO2 catalysts were synthesized by the different methods to derive the optimal synthetic method and to investigate the effect of the preparation method on the physicochemical characteristics of Co–CeO2 catalysts in the high-temperature water-gas shift (HTS) reaction. The Co–CeO2 catalyst synthesized by the sol-gel method featured a strong metal to support interaction and the largest number of oxygen vacancies compared to other catalysts, which affects the catalytic activity. As a result, the Co–CeO2 catalyst synthesized by the sol-gel method exhibited the highest WGS activity among the prepared catalysts, even in severe conditions (high CO concentration: ~38% in dry basis and high gas hourly space velocity: 143,000 h−1).

Cr-Free, Cu Promoted Fe Oxide-Based Catalysts for High-Temperature Water-Gas Shift (HT-WGS) Reaction

Ca, Ni, Co, and Ge promoters were examined as potential candidates to substitute for the current toxic Cr in Cu-promoted Fe oxide-based catalysts for the HT-WGS reaction. The Ca and Ni promoters were found to improve catalyst performance relative to promotion with Cr. The HS-LEIS surface analysis data demonstrate that Ca and Ge tend to segregate on the surface, while Ni, Co, and Cr form solid solutions in the Fe3O4 bulk lattice. The corresponding number of catalytic active sites, redox, and WGS activity values of the catalysts were determined with CO-TPR, CO+H2O-TPSR, and SS-WGS studies, respectively. The poorer HT-WGS performances of the Ge and Co promoters are related to the presence of surface Ge and Co that inhibits catalyst redox ability, with the Co also not stabilizing the surface area of the Fe3O4 support. The Ni promoter uniformly disperses the Cu nanoparticles on the catalyst surface and increases the number of FeOx-Cu interfacial redox sites. The Ca promoter on the catalyst surface, however, enhances the activity of the FeOx-Cu interfacial redox sites. The CO+H2O TPSR results reveal that the redox ability of the active sites follows the SS-WGS performance of the catalysts and show the following trend: 3Cu8CaFe > 3Cu8NiFe ≥ 3Cu8CrFe > 3Cu8CoFe >> 3Cu8GeFe. Furthermore, all the catalysts followed a redox-type reaction mechanism for the HT-WGS reaction.

Steam reforming of polystyrene at a low temperature for high H2/CO gas with bimetallic Ni-Fe/ZrO2 catalyst

Recovery of chemicals and fuels from unrecyclable waste plastics at high temperatures (>800 °C) has received much research attention. Thermodynamic equilibrium calculation suggests that it is possible to perform the low-temperature steam reforming of polystyrene. In this study, we synthesized a Ni-Fe bimetallic catalyst for the low-temperature (500 °C) steam reforming of polystyrene. XRD characterization showed that Ni-Fe alloy was formed in the catalyst. Compared to conventional Ni catalysts, the Ni-Fe bimetallic catalysts can significantly increase the H₂/CO ratio in the produced gas with high gas production yield. The online gas analysis revealed that H₂, CO, and CO₂ were formed in the same temperature range. H₂ and CO were formed simultaneously through steam reforming reactions, and CO₂ was formed through water-gas shift reaction. New morphologies of carbon deposition on the catalyst surface were found, suggesting that wax could be condensed on the catalyst surface at a low temperature.

Reverse Water-Gas Shift Iron Catalyst Derived from Magnetite

The catalytic properties of unsupported iron oxides, specifically magnetite (Fe3O4), were investigated for the reverse water-gas shift (RWGS) reaction at temperatures between 723 K and 773 K and atmospheric pressure. This catalyst exhibited a fast catalytic CO formation rate (35.1 mmol h−1 gcat.−1), high turnover frequency (0.180 s−1), high CO selectivity (> 99%), and high stability (753 K, 45000 cm3h−1gcat.−1) under a 1:1 H2 to CO2 ratio. Reaction rates over the Fe3O4 catalyst displayed a strong dependence on H2 partial pressure (reaction order of ~0.8) and a weaker dependence on CO2 partial pressure (reaction order of 0.33) under an equimolar flow of both reactants. X-ray powder diffraction patterns and XPS spectra reveal that the bulk composition and structure of the post-reaction catalyst was formed mostly of metallic Fe and Fe3C, while the surface contained Fe2+, Fe3+, metallic Fe and Fe3C. Catalyst tests on pure Fe3C (iron carbide) suggest that Fe3C is not an effective catalyst for this reaction at the conditions investigated. Gas-switching experiments (CO2 or H2) indicated that a redox mechanism is the predominant reaction pathway.

The Influence of Cu and Al Additives on Reduction of Iron(III) Oxide: In Situ XRD and XANES Study

The reduction of Fe-based nanocomposite catalysts doped with Al and Cu has been studied using in situ X-ray diffraction (XRD), in situ X-ray absorption near-edge structure (XANES), and temperature-programmed reduction (TPR) techniques. The catalysts have been synthesized by melting of iron, aluminum, and copper salts. According to XRD, the catalysts consist mainly of Fe₂O₃ and Al₂O₃ phases. Alumina is in an amorphous state, whereas iron oxide forms nanoparticles with the protohematite structure. The Al³⁺ cations are partially dissolved in the Fe₂O₃ lattice. Due to strong alumina-iron oxide interaction, the specific surface area of the catalysts increases significantly. TPR and XANES data indicate that copper forms highly dispersed surface CuO nanoparticles and partially dissolves in iron oxide. It has been shown that the reduction of iron(III) oxide by CO proceeds via two routes: a direct two-stage reduction of iron(III) oxide to metal (Fe₂O₃ → Fe₃O₄ → Fe) or an indirect three-stage reduction with the formation of FeO intermediate phases (Fe₂O₃ → Fe₃O₄ → FeO → Fe). The introduction of Al into Fe₂O₃ leads to a decrease in the rate for all reduction steps. In addition, the introduction of Al stabilizes small Fe₃O₄ particles and prevents further sintering of the iron oxide. The mechanism of stabilization is associated with the formation of Fe_{3- x}Al _xO₄ solid solution. The addition of copper to the Fe-Al catalyst leads to the formation of highly dispersed CuO particles on the catalyst surface and a mixed oxide with a spinel-type crystalline structure similar to that of CuFe₂O₄. The low-temperature reduction of Cu²⁺ to Cu⁰ accelerates the Fe₂O₃ → Fe₃O₄ and FeO → Fe transformations but does not affect the Fe₃O₄ → FeO/Fe stages. These changes in the reduction properties significantly affect the catalytic performance of the Fe-based nanocomposite catalysts in the low-temperature oxidation of CO.

Molecular-level understanding of reaction path optimization as a function of shape concerning the metal–support interaction effect of Co/CeO2 on water-gas shift catalysis

In this work, the active sites generated in hydrogen reduction and the reaction pathways for the water gas shift (WGS) reaction over Co/CeO₂ catalysts were studied by in situ XAS and XPS coupled with DFT+U calculations.

Reduction of double manganese–cobalt oxides: in situ XRD and TPR study

The mechanism of reduction of double Mn–Co oxides with hydrogen differs significantly from the processes occurring on simple oxides.

Selective gas phase hydrogenation of nitroarenes over Mo2C-supported Au–Pd

The first reported synthesis of Au–Pd/Mo₂C from colloidal nanoparticles with enhanced selective catalytic hydrogenation of functionalised nitroarenes.

Preparation of mesoporous nanocrystalline alkali promoted chromium free catalysts (Fe2O3–Al2O3–NiO) for a high temperature water gas shift reaction

Alkali promoted-Fe–Al–Ni catalysts exhibited higher activity and lower methanation compared to the unpromoted Fe–Al–Ni catalyst in high temperature water gas shift reaction.