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Metal-foam-structured Ni–Al2O3 catalysts: Wet chemical etching preparation and syngas methanation performance

Paper ID Volume ID Publish Year Pages File Format Full-Text
39031 45801 2016 11 PDF Available
Title
Metal-foam-structured Ni–Al2O3 catalysts: Wet chemical etching preparation and syngas methanation performance
Abstract

•Metal(Ni, Cu, or NiCu-alloy)-foam-structured Ni–Al2O3 are obtained by a facile wet chemical etching method.•This new approach provides combination of high catalytic performance with enhanced heat transfer and high permeability.•Ni–Al2O3/Ni-foam is highly active, selective and stable for CO methanation.•This catalyst is capable of handling a wide range of syngas mixtures.•Enhanced heat transfer is confirmed by experimental measurement and CFD calculation.

Production of substitute natural gas (SNG) by methanation of syngas generated from various carbon sources provides a promising route towards coal clean utilization and sustainable energy future. Monolithic Ni (or Cu, NiCu-alloy)-foam-structured Ni–Al2O3 catalysts were developed by a facile modified wet chemical etching method. The as-prepared catalysts were characterized by X-ray diffraction, scanning electron microscopy, inductively coupled plasma atomic emission spectrometry and H2-temperature programmed reduction. Among these catalysts, Ni–Al2O3/Ni-foam has the most surface active Ni atoms and exhibits the best catalytic methanation performance, achieving 99.9% CO conversion with 90.0% methane selectivity and being stable for at least 1000 h for a feed gas of H2/CO (3/1) at 330 °C and gas hourly space velocity (GHSV) of 5000 h−1. Effects of reaction temperature, reaction pressure and GHSV are also investigated on the catalytic performance of Ni–Al2O3/Ni-foam for CO methanation. Computational fluid dynamics calculation and experimental measurement consistently show that such monolithic Ni–Al2O3/Ni-foam can dramatically reduce the “hotspot” temperature due to its high thermal conductivity. Moreover, the feasibility of our Ni–Al2O3/Ni-foam catalyst for co-methanation of a simulated feed gas from coal gasification is studied as well as CO2 methanation in the presence of high CH4 concentration. We anticipate that our present work might stimulate commercial exploitation of the new-generation structured catalyst and reactor technology for the strongly exothermic syngas methanation toward energy-efficient process for SNG production.

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Keywords
Structured catalyst; Syngas methanation; Foam; Enhanced heat transfer; CFD simulation
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Publisher
Database: Elsevier - ScienceDirect
Journal: Applied Catalysis A: General - Volume 510, 25 January 2016, Pages 216–226
Authors
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Subjects
Physical Sciences and Engineering Chemical Engineering Catalysis
Get Full-Text Now
Don't Miss Today's Special Offer
Price was $35.95
You save - $31
Price after discount Only $4.95
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Full-text PDF Download
Online Support
Any Questions? feel free to contact us