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Article history:
Received 27 June 2008
Received in revised form 16 September 2008
Accepted 17 September 2008
Available online 1 October 2008
The catalytic performance of Ni metal catalysts uniformly covered with layers of silica for propane steam
reforming was compared with the performances of Ni metal catalysts supported on substrates of
magnesia (MgO), alumina (Al2O3) and silica (SiO2). The silica-coated Ni catalysts showed high activity for
propane steam reforming at 873 K. This catalytic activity is higher than the activity of effective light
alkane steam reforming Ni/Al2O3 and Ni/MgO catalysts and we found that the catalytic activity of the
silica-supported Ni metal was poor. The coverage of Ni metal particles with silica thus improves their
catalytic activity for this reaction. Carbon deposition on silica-coated Ni catalysts during the steam
reforming of propane at 873 K was lower than that on Ni/MgO and Ni/Al2O3. Ni K-edge XANES and EXAFS
spectra of silica-coated Ni catalyst showed a strong interaction between Ni metal and silica. This
interaction prevents the sintering of Ni metal particles during the propane steam reforming, which
results in the reduction of carbon deposition on silica-coated Ni catalysts. These properties of silicacoated Ni catalysts result in high catalytic activity and improved catalyst stability.
2008 Elsevier B.V. All rights reserved.
Keywords:
Propane steam reforming
Synthesis gas
Ni catalysts
Silica coating
Carbon deposition
1. Introduction
H2 is a clean fuel because CO2 is not emitted when it is used as a
fuel for polymer-electrolyte fuel cells (PEFCs). H2 has been
produced through steam reforming of CH4, which is a main
component of natural gas, followed by a water-gas shift reaction of
CO. Supported Ni catalysts are generally used for the steam
reforming of CH4 [15]. These catalysts are, however, deactivated
by the sintering of Ni metal and by coke formation. The
development of Ni catalysts which are resistant to Ni metal
particle sintering and to coke formation is thus desired.
Steam reforming of CH4 is a promising technology for the
supply of H2 to stationary fuel cells due to an abundance of CH4 as
natural gas and as CH4 hydrate. H2 production facilities should be
constructed near natural gas pipelines due to energy costs
associated with storage and transportation of liqueed natural
gas. The energy requirement is due to the low liquefaction
temperature of CH4. Urban infrastructure exists for the distribution
of CH4 as utility gas but remote locations need alternative energy
sources for H2 production. Liqueed petroleum gas (LPG), which
mainly contains propane, is a promising alternative energy source
for H2 production because LPG is condensed at higher tempera-
tures than natural gas. The steam reforming of LPG should thus be
investigated for the potential use in fuel cells. Supported Ni
catalysts have been investigated for the use in the steam reforming
of LPG but were found to be deactivated by coke formation [610].
These reports indicated that the formation of coke is more
pronounced in the steam reforming of LPG than in the steam
reforming of natural gas. The development of Ni catalysts with high
resistance to coke formation is thus desired.
Our group has previously reported excellent catalytic performance for the partial oxidation of CH4 into synthesis gas using a
silica-coated Ni catalyst [11]. The Ni metal nanoparticles within
the silica-coated Ni catalyst were not aggregated during the partial
oxidation of CH4 at 973 K because they were uniformly covered by
layers of silica. In addition, this catalyst was not deactivated by
coke formation during the partial oxidation of CH4. This study was
undertaken with the expectation that silica-coated Ni catalysts
would be effective for the steam reforming of LPG. The silicacoated Ni metal catalyst was thus applied to the steam reforming
of propane.
2. Experimental
2.1. Preparation of catalysts
* Corresponding authors. Tel.: +81 92 802 2752; fax: +81 92 802 2752.
E-mail address: takenaka@chem-eng.kyushu-u.ac.jp (S. Takenaka).
0926-860X/$ see front matter 2008 Elsevier B.V. All rights reserved.
doi:10.1016/j.apcata.2008.09.017
190
2 moles of H2 produced
100
total moles of H atoms in the feed
Fig. 1. TEM images of Ni(10 wt%)/SiO2 (a) and coat-Ni(10 wt%) (b).
Fig. 2. XRD patterns of Ni(10 wt%)/MgO, Ni(10 wt%)/SiO2, Ni(20 wt%)/Al2O3 and
coat-Ni (10 wt%).
and 52.08 in the XRD patterns for all the Ni catalysts. These peaks,
however, have a low intensity for coat-Ni and Ni/MgO but the
results do indicate that Ni metal crystallites are present in all the Ni
catalysts. The formation of a solid solution between NiO and MgO
is known to occur and the Ni species within the solid solution are
not easily reduced to Ni metal in the presence of H2, even at 973 K
[15]. The diffraction lines due to Ni metal in the XRD pattern of Ni/
MgO are, therefore, very small in intensity.
Fig. 3. Ni K-edge XANES spectra of different Ni catalysts and reference samples (Ni
foil and NiO). (a) Ni foil; (b) Ni (10 wt%)/SiO2; (c) Ni (20 wt%)/Al2O3, (d) coat-Ni
(10 wt%); (e) Ni (10 wt%)/MgO; (f) NiO.
191
192
RSF for NiO has an intense peak at around 2.7 A due to the second
shell (NiNi) in NiO (the result is not shown). Oxidized Ni species in
Ni/MgO are, therefore, not aggregated but highly dispersed in the
MgO supports, i.e. the formation of a Ni-Mg-O solid solution
occurs.
3.2. Catalytic performance of coat-Ni for steam reforming of propane
Ni/MgO and Ni/Al2O3 catalysts are some of the most effective
catalysts for the steam reforming of light alkanes such as CH4,
ethane and propane. The catalytic performance of coat-Ni for the
steam reforming of propane was thus compared with the
performances of Ni/MgO and Ni/Al2O3. Propane conversion and
H2 yield in the steam reforming of propane over Ni/MgO, Ni/Al2O3
and coat-Ni catalysts with different Ni loading are listed in Table 1.
The quantity of catalyst loaded into the reactor was such that the
Ni content was equivalent in all the reactions. The results shown in
Table 1 were collected at 5 h of time on stream, from the reaction
over each catalyst. H2, CO, CO2 and CH4 were formed in addition to
trace amounts of ethylene and propylene during all the Ni catalyst
reactions. The H2 yield and propane conversion over coat-Ni and
Ni/Al2O3 increased with higher Ni loading. In contrast to coat-Ni
and Ni/Al2O3, the catalytic activity of Ni/MgO for the steam
reforming of propane was lower when the Ni loading increased
from 10 to 20 wt%. The catalytic reactions of Ni (10 wt%)/MgO,
coat-Ni (10 wt%) and Ni (20 wt%)/Al2O3 were then examined.
Table 1 also shows the results of propane steam reforming over the
Ni (10 wt%)/SiO2 catalyst, which was prepared by a conventional
impregnation method. The Ni/SiO2 catalyst did not show any
activity for the steam reforming of propane as no H2 or CO was
formed under the experimental conditions. It was reported that Ni/
SiO2 catalysts were easily deactivated for the steam reforming of
methane [19,20]. The results shown in Table 1 were collected at 5 h
of time on stream. Thus, the Ni/SiO2 would be deactivated at 5 h of
time on steam. Likely, the silica coating of coat-Ni improves the
catalytic activity of the Ni metal for the steam reforming of
propane.
Steam reforming of propane over coat-Ni, Ni/MgO and Ni/Al2O3
catalysts was carried out with different W/F values (W, weight of Ni
atoms in the reactor; F, ow rate of reactants) in order to assess the
catalytic activity of each catalyst. Fig. 5 shows propane conversion
after 5 h of time on stream, as a function of W/F values from the
reactions over the coat-Ni, Ni/MgO and Ni/Al2O3 catalysts. W/F
values ranged from ca. 0.01 to 0.04. All the Ni catalyst reactions had
lower propane conversion as the W/F ratio was reduced. The
propane conversion for coat-Ni was higher than for the other
catalysts over the whole W/F range, indicating that the coat-Ni
catalysts, generally, had the highest activity. As described
previously, the Ni metal crystallites in coat-Ni are smaller than
those in Ni/Al2O3, which also contributes to the higher catalytic
activity of coat-Ni. On the other hand, the Ni metal crystallites in
Ni/MgO are also small, but the fraction of Ni metal to all Ni species
Table 1
Steam reforming of propane over coat-Ni, Ni/MgO, Ni/Al2O3 and Ni/SiO2 at 873 K.
Catalyst
Ni loading (wt%)
H2 yield (%)
Coat-Ni
Coat-Ni
Ni/MgO
Ni/MgO
Ni/Al2O3
Ni/Al2O3
Ni/SiO2
5
10
10
20
10
20
10
21
98
89
46
62
86
<1
21
65
68
42
61
67
0
1
Fig. 6. Change of propane conversion with time on stream in the propane steam
reforming over coat-Ni, Ni/MgO and Ni/Al2O3 at 873 K. P(C3H8) = 5 kPa,
P(H2O) = 15 kPa, P(N2) = 5 kPa and P(Ar) = 76 kPa. Flow rate = 100 ml min1. Mass
of Ni in the reactor = 0.0013 g.
193
Fig. 8. Change of propane conversion with time on stream in the propane steam
reforming over coat-Ni, Ni/MgO and Ni/Al2O3 at 873 K. P(C3H8) = 5 kPa,
P(H2O) = 20 kPa, P(N2) = 5 kPa and P(Ar) = 71 kPa. Flow rate = 100 ml min1. Mass
of Ni in the reactor = 0.0013 g.
Fig. 7. Change of H2 yield and selectivity to CO, CO2 or CH4 with time on stream in
the propane steam reforming over coat-Ni, Ni/MgO and Ni/Al2O3 at 873 K.
P(C3H8) = 5 kPa, P(H2O) = 15 kPa, P(N2) = 5 kPa and P(Ar) = 76 kPa. Flow rate = 100
ml min1. Mass of Ni in the reactor = 0.0013 g.
lower than those for the Ni/MgO and Ni/Al2O3 catalysts. The
selectivity to CO was similar for all the catalysts. These results
imply that methanation of CO2 preferentially occurs over the coatNi catalyst.
In a further experiment, the molar ratio of propane to steam in
the steam reforming of propane was changed from 1/3 to 1/4. The
change in propane conversion and the change in H2 yield as well as
the selectivity to CO, CO2 and CH4 as a function of time on stream
are shown in Figs. 8 and 9, respectively. Propane conversions for
the reactions over coat-Ni and Ni/Al2O3 catalysts were higher
when the partial pressure of steam was increased, while the
propane conversion for Ni/MgO did not depend appreciably on the
partial pressure of steam. All the catalysts deactivated slightly with
time on stream, but the rate of deactivation was negligible
compared to the reactions at the propane/steam ratio = 1/3. The
increase in the partial pressure of steam is likely to mitigate the
carbon deposition on the Ni catalysts during the steam reforming
of propane. The selectivity to CO, CO2 and CH4 for all the catalysts
did not depend, signicantly, on the partial pressure of steam.
The amount of carbon deposited on the Ni catalysts during the
reactions for 5 h is shown in Fig. 10. The amount of carbon
deposited on the coat-Ni was signicantly less than the amounts of
carbon deposited on Ni/MgO and Ni/Al2O3. The coat-Ni catalyst
showed high resistance to carbon deposition in the reaction even at
lower partial pressures of steam. The amount of carbon deposited
on the supported Ni catalysts during the steam reforming of
Fig. 9. Change of H2 yield and selectivity to CO, CO2 or CH4 with time on stream in
the propane steam reforming over coat-Ni, Ni/MgO and Ni/Al2O3 at 873 K.
P(C3H8) = 5 kPa, P(H2O) = 20 kPa, P(N2) = 5 kPa and P(Ar) = 71 kPa. Flow rate = 100
ml min1. Mass of Ni in the reactor = 0.0013 g.
194
hydrocarbons generally increases as the conversion of hydrocarbons increases. The catalytic activity of coat-Ni was higher than
that of the other catalysts tested in this study. We thus conclude
that the coat-Ni catalyst has a high resistance to carbon deposition
during the steam reforming of hydrocarbons. Carbon deposition
from hydrocarbons on the supported Ni catalysts is more prevalent
when the Ni metal particle is larger [2123]. As previously
described, Ni metal particles in coat-Ni were smaller than those in
Ni/Al2O3. The Ni metal particles in coat-Ni are not aggregated
during the propane steam reforming because the metal particles
are covered with silica. Thus, coat-Ni catalyst has a high resistance
to carbon deposition during the steam reforming of propane. It is
reported that carbon is deposited as lamentous carbon during the
steam reforming of hydrocarbons over the supported Ni catalysts
[24,25]. Carbon atoms from hydrocarbons are deposited on the
surface of Ni metal particles, supported on carriers, during the
steam reforming of hydrocarbons, and then carbon atoms diffuse
on the surfaces and/or in the bodies of the Ni metal particles,
resulting in the formation of lamentous carbon [26,27]. Ni metal
particles in the supported Ni catalysts are thus not present on the
carrier, but are present at the tip of lamentous carbon, when
carbons are deposited on the Ni catalysts. It should be noted that Ni
metal particles in coat-Ni are covered with silica layers. The Ni
metal particles in coat-Ni strongly interact with silica, as shown by
its XANES spectrum. The strong interaction between silica and Ni
metal particles in coat-Ni should prevent detachment of Ni metal
particles from silica supports, which results in high resistance to
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