article · Journal of CO2 Utilization
Dry reforming of methane converts greenhouse gases into hydrogen-rich syngas, but finding stable, cost-effective catalysts remains a technical hurdle. A catalyst formulation combining nickel as an active metal, a mixed zirconia-alumina support, and a strontium promoter addresses these operational demands. Testing across various strontium loadings showed that adding three weight percent strontium enhances the reduction of nickel species and accelerates the removal of carbon deposits via carbon dioxide. This composition introduces additional strong basic sites that suppress unwanted hydrogen-consuming side reactions. In performance evaluations, the optimised catalyst achieved an initial hydrogen yield of approximately 82 percent and sustained a yield of 79 percent over 51 hours of continuous operation. Further statistical process optimisation produced an experimental hydrogen yield of 87.4 percent with verified stability over ten hours, presenting a durable formulation for dry reforming applications.
Dry reforming of methane turns two major greenhouse gases, methane and carbon dioxide, into valuable synthesis gas for fuel and chemical production. Conventional nickel catalysts often suffer from rapid deactivation caused by carbon accumulation. By improving durability and suppressing side reactions, this strontium-promoted formulation demonstrates a practical pathway to producing hydrogen efficiently without relying on scarce, expensive precious metals.
The research presents an applied and tested catalyst design intended for industrial dry reforming of methane to generate hydrogen-rich syngas. Potential adopters include chemical manufacturers, synthetic fuel producers, and industrial gas companies seeking cost-effective alternatives to precious-metal catalysts. The technology sits at a laboratory validation stage, having demonstrated operational stability over 51 hours and process optimisation at bench scale, but it requires further long-duration testing and scaling to prove commercial viability.
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An urgent need exists in the dry reforming of methane (DRM) community for a cost-effective and high-performance catalyst system to facilitate the industrial production of H2-rich syngas. In this study, we propose a catalyst composed of a 10 wt% ZrO2-90 wt% Al2O3 support, Ni as active sites, and a strontium promoter, which offers a promising solution. Characterization of the 5NixSr/10Zr+Al catalyst series (x = 0–4 wt%) was conducted using XRD, surface area and porosity analysis, and TPR, TPO, TPD techniques, revealing the stability of metallic Ni derived from the reduction of "moderately interacted NiO-species" under oxidizing-reducing conditions. Incorporating 3 wt% Sr in the 5Ni/10Zr+Al catalyst enhanced reducibility and promoted efficient oxidation of carbon deposits by CO2. The resulting 5Ni3Sr/10Zr+Al catalyst exhibited additional strong basic sites, leading to ∼82% H2 yield and effective inhibition of parallel H2-consuming reactions. Remarkably, the H2 yield remained stable at ∼79% over a 51-hour time on stream, while process optimization using response surface methodology yielded an optimized H2 yield of 89% under specific conditions. Experimental validation demonstrated an H2 yield of 87.4% with excellent stability for a 10-hour time on stream. Overall, the proposed catalyst system demonstrates cost-effectiveness, high performance, and stability, making it a promising candidate for DRM applications.
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DOI: 10.1016/j.jcou.2023.102578
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