Four challenges for nickel steam-reforming catalysts

Single noble metal atoms and ultrafine metal clusters catalysts tend to sinter into aggregated particles at elevated temperatures, driven by the decrease of metal surface free energy. Herein, we report an unexpected phenomenon that noble metal nanoparticles (Pd, Pt, Au-NPs) can be transformed to thermally stable single atoms (Pd, Pt, Au-SAs) above 900 °C in an inert atmosphere. The atomic dispersion of metal single atoms was confirmed by aberration-corrected scanning transmission electron microscopy and X-ray absorption fine structures. The dynamic process was recorded by in situ environmental transmission electron microscopy, which showed competing sintering and atomization processes during NP-to-SA conversion. Further, density functional theory calculations revealed that high-temperature NP-to-SA conversion was driven by the formation of the more thermodynamically stable Pd-N4 structure when mobile Pd atoms were captured on the defects of nitrogen-doped carbon. The thermally stable single atoms (Pd-SAs) exhibited even better activity and selectivity than nanoparticles (Pd-NPs) for semi-hydrogenation of acetylene.

Direct observation of noble metal nanoparticles transforming to thermally stable single atoms.

Steam reforming of methane is an extremely important process for the hydrogen and syngas production. Nickel-based catalysts have been extensively employed in the industrial process of steam reforming because of their high activity, low cost, and the plentiful supply of Nickel. Nickel-based catalysts have also shown high activity for CO2 reforming of methane, which has been considered as a good option, with consumption of a significant amount of carbon dioxide. However, a major challenge is that Ni catalysts have a high thermodynamic potential for coke formation during reforming reactions. For steam reforming, coke formation induces deactivation of the catalyst, especially if the carbon forms as carbon filaments. The filamentous carbon material has a high mechanical strength and can cause mechanical deformation of the catalyst. For CO2 reforming, coke formation over Ni catalyst is even more serious and leads to rapid deactivation of the catalyst. It is highly desired to design and synthesize a coke resistant Ni catalyst not only for reforming of methane, but also for reforming of other hydrocarbons (including biomass derived hydrocarbons). Herein we summarize the very recent progresses in the design, synthesis, and characterization of coke resistant Ni catalysts for steam and CO2 reforming of methane. The progresses in the use of promoters, in the effect of supporting materials and in the preparation methods have been discussed. The thermal stability, regeneration, and future development of coke resistant Ni catalysts for these processes are also briefly addressed.

Progresses in the Preparation of Coke Resistant Ni-based Catalyst for Steam and CO2 Reforming of Methane

Fundamental mechanisms limiting solid oxide fuel cell durability

Methanation of coal-or biomass-derived carbon oxides for production of synthetic natural gas (SNG) is gaining considerable interest due to energy issues and the opportunity of reducing greenhouse gases by carbon dioxide conversion. The key component of the methanation process is the catalyst design. Ideally, the catalyst should show high activity at low temperatures (200-300 degrees C) and high stability at high temperatures (600-700 degrees C). In the past decades, various methanation catalysts have been investigated, among which transition metals including Ni, Fe, Co, Ru, Mo, etc. dispersed on metal oxide supports such as Al2O3, SiO2, TiO2, ZrO2, CeO2 etc. have received great attention due to their relatively high catalytic activity and selectivity. Furthermore, over the past few years, great efforts have been made both in methanation catalysts development and reaction mechanism investigation. Here we provide a comprehensive review to these most advancements, covering the reaction thermodynamics, mechanism and kinetics, the effects of catalyst active components, supports, promoters and preparation methods, hoping to outline the pathways for the future methanation catalysts design and development for SNG production.

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Recent advances in methanation catalysts for the production of synthetic natural gas

Sintering of nickel steam-reforming catalysts: effects of temperature and steam and hydrogen pressures

Supported nickel catalysts are widely used in the steam-reforming process for industrial scale production of hydrogen and synthesis gas. This paper provides a study of sintering in nickel-based catalysts (Ni/Al 2 O 3 and Ni/MgAl 2 O 4 ). Specifically the influence of time, temperature, atmosphere, nickel-carrier interactions and dopants on the rate of sintering is considered. To probe the sintering kinetics, all catalysts were analyzed by sulfur chemisorption to determine the Ni surface area. Furthermore selected samples were further analyzed using X-ray diffraction (XRD), mercury porosimetry, BET area measurements, and electron microscopy (EM). The observed sintering rates as a function of time, temperature, and P H 2 O / P H 2 ratio were consistent with recent model predictions [J. Sehested, J.A.P. Gelten, I.N. Remediakis, H. Bengaard, J.K. Norskov, J. Catal. 223 (2004) 432] over a broad range of environmental conditions. However, exposing the catalysts to severe sintering conditions the loss of nickel surface area is faster than model predictions and the deviation is attributed to a change in the sintering mechanism and nickel removal by nickel-carrier interactions. Surprisingly, alumina-supported Ni particles grow to sizes larger than the particle size of the carrier indicating that the pore diameter does not represent an upper limit for Ni particle growth. The effects of potassium promotion and sulfur poisoning on the rates of sintering were also investigated. No significant effects of the dopants were observed after ageing at ambient pressure. However, at high pressures of steam and hydrogen (31 bar and H 2 O:H 2  = 10:1) potassium promotion increased the sintering rate relative to that of the unpromoted catalyst. Sulfur also enhances the rate of sintering at high pressures, but the effect of sulfur is less than for potassium.

Johannes A.P. Gelten

Papers

Sintering of nickel steam-reforming catalysts: effects of temperature and steam and hydrogen pressures

Sintering of nickel catalysts: Effects of time, atmosphere, temperature, nickel-carrier interactions, and dopants