Syngas production via combined dry and steam reforming methane over Ni-based catalyst: A review

Syngas production via combined dry and steam reforming methane over Ni-based catalyst: A review

SYED MUHAMMAD WAJAHAT ul Hasnain, AHMAD Salam Farooqi, BAMIDELE Victor Ayodele, BAWADI Abdullah

Abstract. Global energy consumption has eventually increased as a result of the growing world population. Various problems arise as a result. The accumulation of greenhouse gases (GHGs), which led to a shift in the world’s climate, is the most problematic. Combined dry and steam reforming of methane (CDRSM) is a highly advantageous method since it uses two of the most significant GHGs, CH4 and CO2, to produce syngas, an intermediate product to produce valuable fuels. Ni-based catalysts are inexpensive, compared to many noble metals, and exhibit good reaction activity. However, deactivation, coking, and sintering of catalysts continue to be the major obstacles to commercialization. Due to better and more stable catalytic structure, which is both coke and sintering resistant at high temperatures, bimetallic catalysts have established increased activity and prolonged durability when compared to monometallic catalysts. This review highlights recent advancements in Ni-based catalysts for CDSRM by emphasizing factors such as catalyst support, bimetallic catalyst, promoters, and strong metal-support interactions (SMSI).

Keywords
Catalyst Development, Ni-Based Catalysts, Syngas Production, CDSRM

Published online 5/20/2023, 11 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: SYED MUHAMMAD WAJAHAT ul Hasnain, AHMAD Salam Farooqi, BAMIDELE Victor Ayodele, BAWADI Abdullah, Syngas production via combined dry and steam reforming methane over Ni-based catalyst: A review, Materials Research Proceedings, Vol. 29, pp 17-27, 2023

DOI: https://doi.org/10.21741/9781644902516-3

The article was published as article 3 of the book Sustainable Processes and Clean Energy Transition

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

References
[1] X. Li, “Diversification and localization of energy systems for sustainable development and energy security,” Energy Policy, vol. 33, no. 17, pp. 2237–2243, 2005, https://doi.org/10.1016/j.enpol.2004.05.002
[2] P. Li, Y. H. Park, D. J. Moon, N. C. Park, and Y. C. Kim, “Carbon deposition onto Ni-Based catalysts for combined steam/CO2reforming of methane,” J. Nanosci. Nanotechnol., vol. 16, no. 2, pp. 1562–1566, Feb. 2016, https://doi.org/10.1166/jnn.2016.12006
[3] N. Apergis, “Oil prices and corporate high-yield spreads: Evidence from panels of nonenergy and energy European firms,” Q. Rev. Econ. Financ., vol. 72, pp. 34–40, 2019, https://doi.org/10.1016/j.qref.2019.01.012
[4] S. Li and J. Gong, “Strategies for improving the performance and stability of Ni-based catalysts for reforming reactions,” Chem. Soc. Rev., vol. 43, no. 21, pp. 7245–7256, Oct. 2014, https://doi.org/10.1039/C4CS00223G
[5] M. Saunois, R. B. Jackson, P. Bousquet, B. Poulter, and J. G. Canadell, “The growing role of methane in anthropogenic climate change,” Environ. Res. Lett., vol. 11, no. 12, 2016, https://doi.org/10.1088/1748-9326/11/12/120207
[6] E. J. Dlugokencky, L. P. Steele, P. M. Lang, and K. A. Masarie, “Global Monitoring Laboratory – Carbon Cycle Greenhouse Gases,” J. Geophy. Res., vol. 99, no. D8, pp. 17021–17043, 1994, Accessed: Jul. 01, 2022. [Online]. Available: https://gml.noaa.gov/ccgg/trends/global.html
[7] “Inventory of U.S. Greenhouse Gas Emissions and Sinks | US EPA.” https://www.epa.gov/ghgemissions/inventory-us-greenhouse-gas-emissions-and-sinks (accessed Apr. 28, 2022).
[8] B. M. Al–Swai et al., “Low-temperature catalytic conversion of greenhouse gases (CO2 and CH4) to syngas over ceria-magnesia mixed oxide supported nickel catalysts,” Int. J. Hydrogen Energy, vol. 46, no. 48, pp. 24768–24780, 2021, https://doi.org/10.1016/j.ijhydene.2020.04.233
[9] N. Yang and R. Wang, “Sustainable technologies for the reclamation of greenhouse gas CO2,” J. Clean. Prod., vol. 103, pp. 784–792, 2015, https://doi.org/10.1016/j.jclepro.2014.10.025
[10] A. S. Farooqi et al., “Catalytic conversion of greenhouse gases (CO2 and CH4) to syngas over Ni-based catalyst: Effects of Ce-La promoters,” Arab. J. Chem., vol. 13, no. 6, pp. 5740–5749, Jun. 2020, https://doi.org/10.1016/j.arabjc.2020.04.012
[11] M. Yusuf et al., “Syngas production from greenhouse gases using Ni–W bimetallic catalyst via dry methane reforming: Effect of W addition,” Int. J. Hydrogen Energy, vol. 46, no. 53, pp. 27044–27061, 2021, https://doi.org/10.1016/j.ijhydene.2021.05.186
[12] J. S. Yu, J. M. Park, J. H. Kwon, and K. S. Park, “Roles of Al2O3 coating layer on an ordered mesoporous Ni/m-Al2O3 for combined steam and CO2 reforming with CH4,” Fuel, vol. 3, no. July 2022, pp. 37–38, 2023, https://doi.org/10.1016/j.fuel.2022.125702
[13] Y. Zhang et al., “Combined steam and CO2 reforming of methane over Co–Ce/AC-N catalyst: Effect of preparation methods on catalyst activity and stability,” Int. J. Hydrogen Energy, vol. 47, no. 5, pp. 2914–2925, 2022, https://doi.org/10.1016/j.ijhydene.2021.10.202
[14] T. J. Siang et al., “Methane bi-reforming over boron-doped Ni/SBA-15 catalyst: Longevity evaluation,” Int. J. Hydrogen Energy, vol. 44, no. 37, pp. 20839–20850, 2019, https://doi.org/10.1016/j.ijhydene.2018.06.123
[15] G. A. Olah, A. Goeppert, M. Czaun, and G. K. S. Prakash, “Bi-reforming of methane from any source with steam and carbon dioxide exclusively to metgas (CO-2H2) for methanol and hydrocarbon synthesis,” J. Am. Chem. Soc., vol. 135, no. 2, pp. 648–650, 2013, https://doi.org/10.1021/ja311796n
[16] M. Yusuf, A. S. Farooqi, M. A. Alam, L. K. Keong, K. Hellgardt, and B. Abdullah, “Response surface optimization of syngas production from greenhouse gases via DRM over high performance Ni–W catalyst,” Int. J. Hydrogen Energy, no. xxxx, 2021, https://doi.org/10.1016/j.ijhydene.2021.05.153
[17] W. J. Jang et al., “Combined steam and carbon dioxide reforming of methane and side reactions: Thermodynamic equilibrium analysis and experimental application,” Appl. Energy, vol. 173, pp. 80–91, 2016, https://doi.org/10.1016/j.apenergy.2016.04.006
[18] G. A. Olah, G. K. S. Prakash, A. Goeppert, M. Czaun, and T. Mathew, “Self-sufficient and exclusive oxygenation of methane and its source materials with oxygen to methanol via metgas using oxidative bi-reforming,” J. Am. Chem. Soc., vol. 135, no. 27, pp. 10030–10031, 2013, https://doi.org/10.1021/ja405439c
[19] V. Dal Santo, A. Gallo, A. Naldoni, M. Guidotti, and R. Psaro, “Bimetallic heterogeneous catalysts for hydrogen production,” Catal. Today, vol. 197, no. 1, pp. 190–205, Dec. 2012, https://doi.org/10.1016/j.cattod.2012.07.037
[20] S. Yu, Y. Hu, H. Cui, Z. Cheng, and Z. Zhou, “Ni-based catalysts supported on MgAl2O4 with different properties for combined steam and CO2 reforming of methane,” Chem. Eng. Sci., vol. 232, p. 116379, 2021, https://doi.org/10.1016/j.ces.2020.116379
[21] G. A. Olah, “Beyond oil and gas: The methanol economy,” Angew. Chemie – Int. Ed., vol. 44, no. 18, pp. 2636–2639, 2005, https://doi.org/10.1002/anie.200462121
[22] B. Abdullah, N. A. Abd Ghani, and D. V. N. Vo, “Recent advances in dry reforming of methane over Ni-based catalysts,” J. Clean. Prod., vol. 162, pp. 170–185, 2017, https://doi.org/10.1016/j.jclepro.2017.05.176
[23] K. Jabbour, “Tuning combined steam and dry reforming of methane for ‘metgas’ production: A thermodynamic approach and state-of-the-art catalysts,” Journal of Energy Chemistry, vol. 48. Elsevier B.V., pp. 54–91, Sep. 01, 2020. https://doi.org/10.1016/j.jechem.2019.12.017
[24] C. C. Chong, S. N. Bukhari, Y. W. Cheng, H. D. Setiabudi, A. A. Jalil, and C. Phalakornkule, “Robust Ni/Dendritic fibrous SBA-15 (Ni/DFSBA-15) for methane dry reforming: Effect of Ni loadings,” Appl. Catal. A Gen., vol. 584, no. May, 2019, https://doi.org/10.1016/j.apcata.2019.117174
[25] N. Laosiripojana and S. Assabumrungrat, “Catalytic dry reforming of methane over high surface area ceria,” Appl. Catal. B Environ., vol. 60, no. 1–2, pp. 107–116, Sep. 2005, https://doi.org/10.1016/J.APCATB.2005.03.001
[26] G. Mallikarjun, T. V. Sagar, S. Swapna, N. Raju, P. Chandrashekar, and N. Lingaiah, “Hydrogen rich syngas production by bi-reforming of methane with CO2over Ni supported on CeO2-SrO mixed oxide catalysts,” Catal. Today, vol. 356, no. December 2019, pp. 597–603, 2020, https://doi.org/10.1016/j.cattod.2020.01.005
[27] C. C. Chong, N. Abdullah, S. N. Bukhari, N. Ainirazali, L. P. Teh, and H. D. Setiabudi, “Hydrogen production via CO2 reforming of CH4 over low-cost Ni/SBA-15 from silica-rich palm oil fuel ash (POFA) waste,” Int. J. Hydrogen Energy, vol. 44, no. 37, pp. 20815–20825, 2019, https://doi.org/10.1016/j.ijhydene.2018.06.169
[28] B. C. Ekeoma, M. Yusuf, K. Johari, and B. Abdullah, “Mesoporous silica supported Ni-based catalysts for methane dry reforming: A review of recent studies,” Int. J. Hydrogen Energy, no. xxxx, 2022, https://doi.org/10.1016/j.ijhydene.2022.05.297
[29] S. Singh et al., “Metgas production from Bi-reforming of methane over lamodified santa barbara amorphous-15 supported nickel catalyst,” Chem. Eng. Trans., vol. 56, pp. 1573–1578, 2017, https://doi.org/10.3303/CET1756263
[30] Y. Tian, X. Ma, X. Chen, and C. Zhang, “Effect of Ni-Co bimetallic core-shell catalyst for coke resistance in CO2 reforming of biomass Tar,” J. Anal. Appl. Pyrolysis, vol. 164, p. 105539, Jun. 2022, https://doi.org/10.1016/j.jaap.2022.105539
[31] M. A. Salaev, L. F. Liotta, and O. V. Vodyankina, “Lanthanoid-containing Ni-based catalysts for dry reforming of methane: A review,” Int. J. Hydrogen Energy, vol. 47, no. 7, pp. 4489–4535, 2022, https://doi.org/10.1016/j.ijhydene.2021.11.086
[32] S. K. Ryi, S. W. Lee, J. W. Park, D. K. Oh, J. S. Park, and S. S. Kim, “Combined steam and CO2 reforming of methane using catalytic nickel membrane for gas to liquid (GTL) process,” Catal. Today, vol. 236, no. PART A, pp. 49–56, Nov. 2014, https://doi.org/10.1016/j.cattod.2013.11.001
[33] A. S. Al-Fatesh et al., “CO2-reforming of methane to produce syngas over Co-Ni/SBA-15 catalyst: Effect of support modifiers (Mg, la and Sc) on catalytic stability,” J. CO2 Util., vol. 21, no. March, pp. 395–404, 2017, https://doi.org/10.1016/j.jcou.2017.08.001
[34] S. C. Baek, J. W. Bae, J. Y. Cheon, K. W. Jun, and K. Y. Lee, “Combined steam and carbon dioxide reforming of methane on Ni/MgAl 2O4: Effect of CeO2 promoter to catalytic performance,” Catal. Letters, vol. 141, no. 2, pp. 224–234, Nov. 2011, https://doi.org/10.1007/s10562-010-0483-0
[35] L. Zhu, Z. Lv, X. Huang, J. Ran, J. Chen, and C. Qin, “Understanding the role of support structure in methane dry reforming for syngas production,” Fuel, vol. 327, no. June, p. 125163, 2022, https://doi.org/10.1016/j.fuel.2022.125163
[36] N. D. Charisiou et al., “Syngas production via the biogas dry reforming reaction over nickel supported on modified with CeO2 and/or La2O3 alumina catalysts,” J. Nat. Gas Sci. Eng., vol. 31, pp. 164–183, Apr. 2016, https://doi.org/10.1016/J.JNGSE.2016.02.021
[37] M. A. Al-Nakoua and M. H. El-Naas, “Combined steam and dry reforming of methane in narrow channel reactors,” Int. J. Hydrogen Energy, vol. 37, no. 9, pp. 7538–7544, May 2012, https://doi.org/10.1016/J.IJHYDENE.2012.02.031
[38] H. S. Roh et al., “Combined reforming of methane over supported Ni catalysts,” Catal. Letters, vol. 117, no. 1–2, pp. 85–90, Aug. 2007, https://doi.org/10.1007/s10562-007-9113-x
[39] J. W. Bae, A. R. Kim, S. C. Baek, and K. W. Jun, “The role of CeO2-ZrO2 distribution on the Ni/MgAl2O4 catalyst during the combined steam and CO 2 reforming of methane,” React. Kinet. Mech. Catal., vol. 104, no. 2, pp. 377–388, Dec. 2011, https://doi.org/10.1007/S11144-011-0371-7/FIGURES/5
[40] E. Rezaei and L. J. J. Catalan, “Evaluation of CO2utilization for methanol production via tri-reforming of methane,” J. CO2 Util., vol. 42, Dec. 2020, https://doi.org/10.1016/J.JCOU.2020.101272
[41] T. J. Siang et al., “Combined steam and CO2 reforming of methane for syngas production over carbon-resistant boron-promoted Ni/SBA-15 catalysts,” Microporous Mesoporous Mater., vol. 262, pp. 122–132, May 2018, https://doi.org/10.1016/j.micromeso.2017.11.028
[42] T. Stroud et al., “Chemical CO2 recycling via dry and bi reforming of methane using Ni-Sn/Al2O3 and Ni-Sn/CeO2-Al2O3 catalysts,” Appl. Catal. B Environ., vol. 224, no. September 2017, pp. 125–135, 2018, https://doi.org/10.1016/j.apcatb.2017.10.047
[43] W. Li, Z. Zhao, P. Ren, and G. Wang, “Effect of molybdenum carbide concentration on the Ni/ZrO2 catalysts for steam-CO2 bi-reforming of methane,” RSC Adv., vol. 5, no. 122, pp. 100865–100872, Nov. 2015, https://doi.org/10.1039/c5ra22237k
[44] K. Jabbour, P. Massiani, A. Davidson, S. Casale, and N. El Hassan, “Ordered mesoporous ‘one-pot’ synthesized Ni-Mg(Ca)-Al2O3 as effective and remarkably stable catalysts for combined steam and dry reforming of methane (CSDRM),” Appl. Catal. B Environ., vol. 201, pp. 527–542, 2017, https://doi.org/10.1016/j.apcatb.2016.08.009
[45] U. S. Mohanty, M. Ali, M. R. Azhar, A. Al-Yaseri, A. Keshavarz, and S. Iglauer, “Current advances in syngas (CO + H2) production through bi-reforming of methane using various catalysts: A review,” Int. J. Hydrogen Energy, vol. 46, no. 65, pp. 32809–32845, 2021, https://doi.org/10.1016/j.ijhydene.2021.07.097
[46] A. S. Farooqi, “Hydrogen-rich syngas production from bi-reforming of greenhouse gases over zirconia modified Ni / MgO catalyst,” no. September, pp. 1–17, 2021, https://doi.org/10.1002/er.7325
[47] M. Yusuf, A. S. Farooqi, L. K. Keong, K. Hellgardt, and B. Abdullah, “Contemporary trends in composite Ni-based catalysts for CO2 reforming of methane,” Chem. Eng. Sci., vol. 229, p. 116072, 2021, https://doi.org/10.1016/j.ces.2020.116072
[48] T. J. Siang, H. T. Danh, S. Singh, Q. D. Truong, H. D. Setiabudi, and D. V. N. Vo, “Syngas production from combined steam and carbon dioxide reforming of methane over Ce-modified silicasupported nickel catalysts,” Chem. Eng. Trans., vol. 56, pp. 1129–1134, 2017, https://doi.org/10.3303/CET1756189
[49] A. S. Al-Fatesh et al., “Greenhouse gases utilization via catalytic reforming with Sc promoted Ni/SBA-15,” Fuel, vol. 330, no. August, p. 125523, 2022, https://doi.org/10.1016/j.fuel.2022.125523
[50] Y. Khani, Z. Shariatinia, and F. Bahadoran, “High catalytic activity and stability of ZnLaAlO4 supported Ni, Pt and Ru nanocatalysts applied in the dry, steam and combined dry-steam reforming of methane,” Chem. Eng. J., vol. 299, pp. 353–366, 2016, https://doi.org/10.1016/j.cej.2016.04.108
[51] X. Wang, S. Xu, W. Yang, X. Fan, Q. Pan, and H. Chen, “Carbon Capture Science & Technology Development of Ni-Co supported on SBA-15 catalysts for non-thermal plasma assisted co-conversion of CO 2 and CH 4 : Results and lessons learnt,” Carbon Capture Sci. Technol., vol. 5, no. September, p. 100067, 2022, https://doi.org/10.1016/j.ccst.2022.100067
[52] S. S. Itkulova, Y. Y. Nurmakanov, S. K. Kussanova, and Y. A. Boleubayev, “Production of a hydrogen-enriched syngas by combined CO2-steam reforming of methane over Co-based catalysts supported on alumina modified with zirconia,” Catal. Today, vol. 299, no. November 2016, pp. 272–279, 2018, https://doi.org/10.1016/j.cattod.2017.07.014
[53] J. Zhang, H. Wang, and A. K. Dalai, “Development of stable bimetallic catalysts for carbon dioxide reforming of methane,” J. Catal., vol. 249, no. 2, pp. 300–310, Jul. 2007, https://doi.org/10.1016/j.jcat.2007.05.004
[54] S. S. Itkulova, G. D. Zakumbaeva, Y. Y. Nurmakanov, A. A. Mukazhanova, and A. K. Yermaganbetova, “Syngas production by bireforming of methane over Co-based alumina-supported catalysts,” Catal. Today, vol. 228, pp. 194–198, 2014, https://doi.org/10.1016/j.cattod.2014.01.013
[55] H. C. Foley, A. J. Hong, J. S. Brinen, L. F. Allard, and A. J. Garratt-Reed, “Bimetallic catalysts comprised of dissimilar metals for the reduction of carbon monoxide with hydrogen,” Appl. Catal., vol. 61, no. 1, pp. 351–375, May 1990, https://doi.org/10.1016/S0166-9834(00)82155-7
[56] J. D. Medrano-García, R. Ruiz-Femenia, and J. A. Caballero, “Multi-objective optimization of combined synthesis gas reforming technologies,” J. CO2 Util., vol. 22, pp. 355–373, 2017, https://doi.org/10.1016/j.jcou.2017.09.019
[57] M. Shakouri, Y. Hu, R. Lehoux, and H. Wang, “CO2 conversion through combined steam and CO2 reforming of methane reactions over Ni and Co catalysts,” Can. J. Chem. Eng., vol. 99, no. 1, pp. 153–165, 2021, https://doi.org/10.1002/cjce.23828
[58] D. He, Y. Zhang, Z. Wang, Y. Mei, and Y. Jiang, “Bi-reforming of Methane with Carbon Dioxide and Steam on Nickel-Supported Binary Mg−Al Metal Oxide Catalysts,” 2020, https://doi.org/10.1021/acs.energyfuels.9b03312
[59] A. F. Cunha, S. Morales-Torres, L. M. Pastrana-Martínez, F. J. Maldonado-Hódar, and N. S. Caetano, “Syngas production by bi-reforming of methane on a bimetallic Ni-ZnO doped zeolite 13X,” Fuel, vol. 311, Mar. 2022, https://doi.org/10.1016/j.fuel.2021.122592
[60] A. F. Cunha et al., “Syngas production by bi-reforming methane on an Ni-K-promoted catalyst using hydrotalcites and filamentous carbon as a support material,” RSC Adv., vol. 10, no. 36, pp. 21158–21173, 2020, https://doi.org/10.1039/d0ra03264f
[61] G. A. Olah, A. Goeppert, M. Czaun, T. Mathew, R. B. May, and G. K. S. Prakash, “Single Step Bi-reforming and Oxidative Bi-reforming of Methane (Natural Gas) with Steam and Carbon Dioxide to Metgas (CO-2H2) for Methanol Synthesis: Self-Sufficient Effective and Exclusive Oxygenation of Methane to Methanol with Oxygen,” J. Am. Chem. Soc., vol. 137, no. 27, pp. 8720–8729, 2015, https://doi.org/10.1021/jacs.5b02029
[62] S. Singh et al., “Bi-reforming of methane on Ni/SBA-15 catalyst for syngas production: Influence of feed composition,” Int. J. Hydrogen Energy, vol. 43, no. 36, pp. 17230–17243, 2018, https://doi.org/10.1016/j.ijhydene.2018.07.136
[63] J. Ashok, Z. Bian, Z. Wang, and S. Kawi, “Ni-phyllosilicate structure derived Ni-SiO2-MgO catalysts for bi-reforming applications: Acidity, basicity and thermal stability,” Catal. Sci. Technol., vol. 8, no. 6, pp. 1730–1742, 2018, https://doi.org/10.1039/c7cy02475d