Single-Step Flame Aerosol Synthesis of Active and Stable Nanocatalysts for the Dry Reforming of Methane

Abstract

We introduce a flame-based aerosol process for producing supported non-noble metal nanocatalysts from inexpensive aqueous metal salt solutions, using catalysts for the dry reforming of methane (DRM) as a prototype. A flame-synthesized nickel-doped magnesia (MgO) nanocatalyst (NiMgO-F) was fully physicochemically characterized and tested in a flow reactor system, where it showed stable DRM activity from 500 to 800 °C. A kinetic study was conducted, and apparent activation energies were extracted for the temperature range of 500−650 °C. It was then compared with a Ni-decorated MgO nanopowder prepared by wet impregnation of (1) flame-synthesized MgO (NiMgO-FI) and (2) a commercial MgO nanopowder (NiMgO-CI) and with (3) a NiMgO catalyst prepared by co-precipitation (NiMgO-CP). NiMgO-F showed the highest catalytic activity per mass and per metallic surface area and was stable for continuous H 2 production at 700 °C for 50 h. Incorporation of potential promoters and co-catalysts was also demonstrated, but none showed significant performance improvement. More broadly, nanomaterials produced by this approach could be used as binary or multicomponent catalysts for numerous catalytic processes.

Alloying Ni–Cu Nanoparticles Encapsulated in SiO2 Nanospheres for Synergistic Catalysts in CO2 Reforming with Methane Reaction

“…Among the techniques for CO 2 upgrading, CO 2 reforming with CH 4 (CRM) converts two main greenhouse gases and produces syngas; the contributions to the environment and energy make it greater to reduce CO 2 emission. Although noble metal catalysts show high activity for the reaction, their high costs are not suitable for industrial applications. − Ni catalysts have comparable activities to noble metals, and their low prices make them more suitable for industrialization. However, CRM is highly endothermic (CO 2 (g) + CH 4 (g) → 2CO­(g) + 2H 2 (g), Δ H 298 = +247 kJ/mol), and a high temperature is required to ensure its progress.…”

CuO Quantum Dots Supported by SrTiO3 Perovskite Using the Flame Spray Pyrolysis Method: Enhanced Activity and Excellent Thermal Resistance for Catalytic Combustion of CO and CH4

“…The catalyst synthesis methods have a prominent influence on the physical and chemical properties of Cu-based perovskite catalysts. Especially, the flame spray pyrolysis (FSP) technologies prepare catalytic materials under the atomic level and downsize particles to form quantum dots or even single atoms, which can effectively enhance the dispersion and maximize the utilization of the atom. , Because of the one-step rapid synthesis of nanoparticles in a dramatically short time, the copper-based or perovskite materials synthesized by FSP have been covered in plenty of research studies. However, although the remarkable advantages are provided by FSP and copper supported on SrTiO 3 has been widely employed in the environmental field, there are few papers on the synthesis of CuO–SrTiO 3 nanoparticles by FSP and their application for CO and CH 4 catalytic combustion.…”

Coking- and Sintering-Resistant Ni Nanocatalysts Confined by Active BN Edges for Methane Dry Reforming

“…The stoichiometry syngas produced in MDR is suitable for preparing high value-added chemicals via Fischer–Tropsch synthesis, which is also crucial for mitigating greenhouse gas emissions. − Considering the low cost and comparable activity with noble metals, Ni-based catalysts have become one of the most promising choices for MDR. However, coking and sintering of active metal causes the serious deactivation of Ni-based catalysts during the MDR process. − Traditional strategies to solve these problems are controlling the Ni particle size via well-confined structured catalysts, − utilizing basic supports to enrich the surface oxygen vacancies, − and adding the secondary metals to increase the dispersion of Ni particles. − Most of the strategies mentioned in the literature utilize metal oxides as the support of catalysts, which can promote the catalytic activity significantly. Nevertheless, the coking issue is still a formidable one to eliminate.…”