Dry reforming of methane with carbon dioxide over NiO–MgO–ZrO 2

Alumina-Magnesia-Supported Ni for Hydrogen Production via the Dry Reforming of Methane: A Cost-Effective Catalyst System

5Ni/MgO and 5Ni/γAl2O3 are pronounced in the line of cheap catalyst systems for the dry reforming of methane. However, the lower reducibility of 5Ni/MgO and the significant coke deposition over 5Ni/γAl2O3 limit their applicability as potential DRM catalysts. The mixing capacity of MgO and Al2O3 may overcome these limitations without increasing the catalyst cost. Herein, a 5Ni/xMg(100 - x)Al (x = 0, 20, 30, 60, 70, and 100 wt. %) catalyst system is prepared, investigated, and characterized with X-ray diffraction, surface area and porosity measurements, H2-temperature programmed reduction, UV-Vis-IR spectroscopy, Raman spectroscopy, thermogravimetry, and transmission electron microscopy. Upon the addition of 20 wt. % MgO into the Al2O3 support, 5Ni/20Mg80Al is expanded and carries both stable Ni sites (derived through the reduction of NiAl2O4) and a variety of CO2-interacting species. CH4 decomposition at Ni sites and the potential oxidation of carbon deposits by CO2-interacting species over 5Ni/20Mg80Al results in a higher 61% H2-yield (against ~55% H2-yield over 5Ni/γAl2O3) with an excellent carbon-resistant property. In the major magnesia support system, the 5Ni/60Mg40Al catalyst carries stable Ni sites derived from MgNiO2 and "strongly interacted NiO-species". The H2-yield over the 5Ni/60Mg40Al catalyst moves to 71%, even against a high coke deposition, indicating fine tuning between the carbon formation and diffusion rates. Ni dispersed over magnesia-alumina with weight ratios of 7/3 and 3/7 exhibit good resistance to coke. Weight ratios of 2/8 and 7/3 contain an adequate amount of reducible and CO2-interactive species responsible for producing over 60% of H2-yield. Weight ratio 6/4 has a proper coke diffusion mechanism in addition to achieving a maximum of 71% H2-yield.

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.

Barium-Promoted Yttria-Zirconia-Supported Ni Catalyst for Hydrogen Production via the Dry Reforming of Methane: Role of Barium in the Phase Stabilization of Cubic ZrO2

Developing cost-effective nonprecious active metal-based catalysts for syngas (H₂/CO) production via the dry reforming of methane (DRM) for industrial applications has remained a challenge. Herein, we utilized a facile and scalable mechanochemical method to develop Ba-promoted (1-5 wt %) zirconia and yttria-zirconia-supported Ni-based DRM catalysts. BET surface area and porosity measurements, infrared, ultraviolet-visible, and Raman spectroscopy, transmission electron microscopy, and temperature-programmed cyclic (reduction-oxidation-reduction) experiments were performed to characterize and elucidate the catalytic performance of the synthesized materials. Among different catalysts tested, the inferior catalytic performance of 5Ni/Zr was attributed to the unstable monoclinic ZrO₂ support and weakly interacting NiO species whereas the 5Ni/YZr system performed better because of the stable cubic ZrO₂ phase and stronger metal-support interaction. It is established that the addition of Ba to the catalysts improves the oxygen-endowing capacity and stabilization of the cubic ZrO₂ and BaZrO₃ phases. Among the Ba-promoted catalysts, owing to the optimal active metal particle size and excess ionic CO₃ ^2- species, the 5Ni4Ba/YZr catalyst demonstrated a high, stable H₂ yield (i.e., 79% with a 0.94 H₂/CO ratio) for up to 7 h of time on stream. The 5Ni4Ba/YZr catalyst had the highest H₂ formation rate, 1.14 mol g^-1 h^-1 and lowest apparent activation energy, 20.07 kJ/mol, among all zirconia-supported Ni catalyst systems.

Coke-Resistant Ni/CeZrO2 Catalysts for Dry Reforming of Methane to Produce Hydrogen-Rich Syngas

Dry reforming of methane was studied over high-ratio zirconia in ceria-zirconia-mixed oxide-supported Ni catalysts. The catalyst was synthesized using co-precipitation and impregnation methods. The effects of the catalyst support and Ni composition on the physicochemical characteristics and performance of the catalysts were investigated. Characterization of the physicochemical properties was conducted using X-ray diffraction (XRD), N2-physisorption, H2-TPR, and CO2-TPD. The results of the activity and stability evaluations of the synthesized catalysts over a period of 240 min at a temperature of 700 °C, atmospheric pressure, and WHSV of 60,000 mL g−1 h−1 showed that the 10%Ni/CeZrO2 catalyst exhibited the highest catalytic performance, with conversions of CH4 and CO2 up to 74% and 55%, respectively, being reached. The H2/CO ratio in the product was 1.4, which is higher than the stoichiometric ratio of 1, indicating a higher formation of H2. The spent catalysts showed minimal carbon deposition based on the thermo-gravimetry analysis, which was <0.01 gC/gcat, so carbon deposition could be neglected.

Hydrogen Yield from CO2 Reforming of Methane: Impact of La2O3 Doping on Supported Ni Catalysts

Development of a transition metal based catalyst aiming at concomitant high activity and stability attributed to distinguished catalytic characteristics is considered as the bottleneck for dry reforming of methane (DRM). This work highlights the role of modifying zirconia (ZrO2) and alumina (Al2O3) supported nickel based catalysts using lanthanum oxide (La2O3) varying from 0 to 20 wt% during dry reforming of methane. The mesoporous catalysts with improved BET surface areas, improved dispersion, relatively lower reduction temperatures and enhanced surface basicity are identified after La2O3 doping. These factors have influenced the catalytic activity and higher hydrogen yields are found for La2O3 modified catalysts as compared to base catalysts (5 wt% Ni-ZrO2 and 5 wt% Ni-Al2O3). Post-reaction characterizations such as TGA have showed less coke formation over La2O3 modified samples. Raman spectra indicates decreased graphitization for La2O3 catalysts. The 5Ni-10La2O3-ZrO2 catalyst produced 80% hydrogen yields, 25% more than that of 5Ni-ZrO2. 5Ni-15La2O3-Al2O3 gave 84% hydrogen yields, 8% higher than that of 5Ni-Al2O3. Higher CO2 activity improved the surface carbon oxidation rate. From the study, the extent of La2O3 loading is dependent on the type of oxide support.

The dry reforming of methane over fly ash modified with different content levels of MgO

Large amounts of industrial waste fly ash (FA) have caused serious pollution to the environment. There are a few reports that this kind of material, with its good thermal stability, can be used as a catalyst support for high-temperature catalytic reactions, and it has a certain application space. Upon the alkali treatment of fly ash, its specific surface area is increased, and it has the potential to be a catalyst support. Using treated fly ash as the carrier, a nickel-based catalyst was prepared via a sol–gel method, and the catalytic performance changes of catalysts with different MgO content levels in the dry reforming of methane are discussed. Under the conditions of a space velocity of 1.8 × 10⁴ mL g⁻¹ h⁻¹ and a reaction temperature of 750 °C, in the presence of Ni/NaFA-M2 (M2 = 20 wt% MgO), the CH₄ conversion rate can reach 84%, and it has good reaction stability. This will provide a way to use fly ash and carry out more research.

Fly ash is a kind of industrial waste, which is used as carrier to prepare nickel based catalyst. The flow chart of catalyst preparation is shown in the figure.

Catalytic Performance of Lanthanum Promoted Ni/ZrO2 for Carbon Dioxide Reforming of Methane

Nickel catalysts supported on zirconium oxide and modified by various amounts of lanthanum with 10, 15, and 20 wt.% were synthesized for CO2 reforming of methane. The effect of La2O3 as a promoter on the stability of the catalyst, the amount of carbon formed, and the ratio of H2 to CO were investigated. In this study, we observed that promoting the catalyst with La2O3 enhanced catalyst activities. The conversions of the feed, i.e., methane and carbon dioxide, were in the order 10La2O3 > 15La2O3 > 20La2O3 > 0La2O3, with the highest conversions being about 60% and 70% for both CH4 and CO2 respectively. Brunauer–Emmett–Teller (BET) analysis showed that the surface area of the catalysts decreased slightly with increasing La2O3 doping. We observed that 10% La2O3 doping had the highest specific surface area (21.6 m2/g) and the least for the un-promoted sample. The higher surface areas of the promoted samples relative to the reference catalyst is an indication of the concentration of the metals at the mouths of the pores of the support. XRD analysis identified the different phases available, which ranged from NiO species to the monoclinic and tetragonal phases of ZrO2. Temperature programmed reduction (TPR) analysis showed that the addition of La2O3 lowered the activation temperature needed for the promoted catalysts. The structural changes in the morphology of the fresh catalyst were revealed by microscopic analysis. The elemental compositions of the catalyst, synthesized through energy dispersive X-ray analysis, were virtually the same as the calculated amount used for the synthesis. The thermogravimetric analysis (TGA) of spent catalysts showed that the La2O3 loading of 10 wt.% contributed to the gasification of carbon deposits and hence gave about 1% weight-loss after a reaction time of 7.5 h at 700 °C.

Promotional effect of magnesium oxide for a stable nickel-based catalyst in dry reforming of methane

The generation of synthesis gas (hydrogen and carbon monoxide mixture) from two global warming gases of carbon dioxide and methane via dry reforming is environmentally crucial and for the chemical industry as well. Herein, magnesium-promoted NiO supported on mesoporous zirconia, 5Ni/xMg–ZrO₂ (x = 0, 3, 5, 7 wt%) were prepared by wet impregnation method and then were tested for syngas production via dry reforming of methane. The reaction temperature at 800 °C was found more catalytically active than that at 700 °C due to the endothermic feature of reaction which promotes efficient CH₄ catalytic decomposition over Ni and Ni–Zr interface as confirmed by CH₄–TSPR experiment. NiO–MgO solid solution interacted with ZrO₂ support was found crucial and the reason for high CH₄ and CO₂ conversions. The highest catalyst stability of the 5Ni/3Mg–ZrO₂ catalyst was explained by the ability of CO₂ to partially oxidize the carbon deposit over the surface of the catalyst. A mole ratio of hydrogen to carbon monoxide near unity (H₂/CO ~ 1) was obtained over 5Ni/ZrO₂ and 5Ni/5Mg–ZrO₂, implying the important role of basic sites. Our approach opens doors for designing cheap and stable dry reforming catalysts from two potent greenhouse gases which could be of great interest for many industrial applications, including syngas production and other value-added chemicals.

H2 Production from Catalytic Methane Decomposition Using Fe/x-ZrO2 and Fe-Ni/(x-ZrO2) (x = 0, La2O3, WO3) Catalysts

An environmentally-benign way of producing hydrogen is methane decomposition. This study focused on methane decomposition using Fe and Fe-Ni catalysts, which were dispersed over different supports by the wet-impregnation method. We observed the effect of modifying ZrO2 with La2O3 and WO3 in terms of H2 yield and carbon deposits. The modification led to a higher H2 yield in all cases and WO3-modified support gave the highest yield of about 90% and was stable throughout the reaction period. The reaction conditions were at 1 atm, 800 °C, and 4000 mL(hgcat)−1 space velocity. Adding Ni to Fe/x-ZrO2 gave a higher H2 yield and stability for ZrO2 and La2O3 + ZrO2-supported catalysts whose prior performances and stabilities were very poor. Catalyst samples were analyzed by characterization techniques like X-ray diffraction (XRD), nitrogen physisorption, temperature-programmed reduction (TPR), thermo-gravimetric analysis (TGA), and Raman spectroscopy. The phases of iron and the supports were identified using XRD while the BET revealed a significant decrease in the specific surface areas of fresh catalysts relative to supports. A progressive change in Fe’s oxidation state from Fe3+ to Fe0 was observed from the H2-TPR results. The carbon deposits on Fe/ZrO2 and Fe/La2O3 + ZrO2 are mainly amorphous, while Fe/WO3 + ZrO2 and Fe-Ni/x-ZrO2 are characterized by graphitic carbon.

Impact of Support (MCF, ZrO2, ZSM-5) on the Efficiency of Ni Catalyst in High-Temperature Conversion of Lignocellulosic Biomass to Hydrogen-Rich Gas

The main objective of this work was to evaluate an impact of a support on the efficiency of nickel catalysts in the high-temperature conversion of lignocellulosic biomass to hydrogen-rich gas. The most important parameters influencing catalytic performance of the catalysts were identified. The properties of three materials (ZSM-5, ZrO₂, and MCF (mesostructured cellular foam)) used as a support differing in surface acidity, surface area, pore structure, ability to interact with an active phase, and resistance to coking, have been studied. The results revealed that Ni/MCF, characterized by large pore size and pore volume, low acidity, small NiO crystallites size, and moderate interaction with the active phase, is the most efficient among studied catalysts, while an application of Ni on ZSM-5 support with high-acidity was not beneficial. The results suggest that structure of the support, in particular larger pore size and a better contact between an active phase and reaction intermediates, play an important role in the formation of gaseous products during thermal decomposition of lignocellulosic feedstock. On the other hand, high acidity of the support did not increase the formation of large amounts of hydrogen-rich gaseous products.

Catalytic Behaviour of Ce-Doped Ni Systems Supported on Stabilized Zirconia under Dry Reforming Conditions

Ni supported on bare and modified ZrO2 samples were synthesized using the incipient wet impregnation method. The t-ZrO2 phase was stabilized by incorporation of La2O3 into ZrO2. Moreover, the influence of CeO2-doping on the physico-chemical and catalytic properties under CO2 reforming conditions was probed. The characterization data of the investigated catalysts were obtained by using XRD, CO2/H2-TPD, BET, TPR, TPO, TGA, XPS and TEM characterization techniques. In the pristine Ni/Zr catalyst, the t-ZrO2 phase transformed into the monoclinic phase. However, upon support modification by La2O3, significant effects on the physicochemical properties were observed due to the monoclinic-to-tetragonal ZrO2 phase transformation also affecting the catalytic activity. As a result, superior activity on the La2O3 modified Ni/Zr catalyst was achieved, while no relevant change in the surface properties and activity of the catalysts was detected after doping by CeO2. The peculiar behavior of the Ni/La-ZrO2 sample was related to higher dispersion of the active phase, with a more pronounced stabilization of the t-ZrO2 phase.

Hierarchically Structured Porous Spinels via an Epoxide-Mediated Sol-Gel Process Accompanied by Polymerization-Induced Phase Separation

Enhancing the activity and stability of catalysts is a major challenge in scientific research nowadays. Previous studies showed that the generation of an additional pore system can influence the catalytic performance of porous catalysts regarding activity, selectivity, and stability. This study focuses on the epoxide-mediated sol-gel synthesis of mixed metal oxides, NiAl₂O₄ and CoAl₂O₄, with a spinel phase structure, a hierarchical pore structure, and Ni and Co contents of 3 to 33 mol % with respect to the total metal content. The sol-gel process is accompanied by a polymerization-induced phase separation to introduce an additional pore system. The obtained mixed metal oxides were characterized with regard to pore morphology, surface area, and formation of the spinel phase. The Brunauer-Emmett-Teller surface area ranges from 74 to 138 m²·g^-1 and 25 to 94 m²·g^-1 for Ni and Co, respectively. Diameters of the phase separation-based macropores were between 500 and 2000 nm, and the mesopore diameters were 10 nm for the Ni-based system and between 20 and 25 nm for the cobalt spinels. Furthermore, Ni-Al spinels with 4, 5, and 6 mol % Ni were investigated in the dry reforming of CH₄ (DRM) with CO₂ to produce H₂ and CO. CH₄ conversions near the thermodynamic equilibrium were observed depending on the Ni content and reaction temperature. The Ni catalysts were further compared to a noble metal-containing catalyst based on a spinel system showing comparable CH₄ conversion and carbon selectivity in the DRM.

Sustainable Conversion of Carbon Dioxide: An Integrated Review of Catalysis and Life Cycle Assessment

CO₂ conversion covers a wide range of possible application areas from fuels to bulk and commodity chemicals and even to specialty products with biological activity such as pharmaceuticals. In the present review, we discuss selected examples in these areas in a combined analysis of the state-of-the-art of synthetic methodologies and processes with their life cycle assessment. Thereby, we attempted to assess the potential to reduce the environmental footprint in these application fields relative to the current petrochemical value chain. This analysis and discussion differs significantly from a viewpoint on CO₂ utilization as a measure for global CO₂ mitigation. Whereas the latter focuses on reducing the end-of-pipe problem "CO₂ emissions" from todays' industries, the approach taken here tries to identify opportunities by exploiting a novel feedstock that avoids the utilization of fossil resource in transition toward more sustainable future production. Thus, the motivation to develop CO₂-based chemistry does not depend primarily on the absolute amount of CO₂ emissions that can be remediated by a single technology. Rather, CO₂-based chemistry is stimulated by the significance of the relative improvement in carbon balance and other critical factors defining the environmental impact of chemical production in all relevant sectors in accord with the principles of green chemistry.