Method of dry reforming of methane

Patent metadata

Field	Value
Publication number	US-11724937-B2
Application number	US-202217573242-A
Country	US
Kind code	B2
Filing date	Jan 11, 2022
Priority date	Dec 22, 2021
Publication date	Aug 15, 2023
Grant date	Aug 15, 2023

Abstract

A method of dry reforming of methane (CH4) is provided. The method includes contacting at a temperature of 500 to 1000 degree Celsius (° C.) a reactant gas mixture including methane and carbon dioxide (CO2) with a bimetallic supported catalyst. The bimetallic supported catalyst includes a porous catalyst support and a bimetallic catalyst. The porous catalyst support includes aluminum oxide (Al2O3) and magnesium oxide (MgO). The bimetallic catalyst includes nickel (Ni) and copper (Cu) disposed on the porous catalyst support. The method further includes collecting a product gas mixture including hydrogen (H2) and carbon monoxide (CO). The bimetallic supported catalyst includes 8 to 16 weight percent (wt. %) nickel and 2 to 14 wt. % copper, each based on a total weight of bimetallic supported catalyst.

First claim

The invention claimed is:

1. A method of dry reforming of methane (CH 4 ), comprising
contacting at a temperature of 500 to 1000 degree Celsius (° C.) a reactant gas mixture comprising methane and carbon dioxide (CO 2 ) with a bimetallic supported catalyst comprising a porous catalyst support comprising aluminum oxide (Al 2 O 3 ) and magnesium oxide (MgO) and a bimetallic catalyst comprising nickel (Ni) and copper (Cu) disposed on the porous catalyst support; and
collecting a product gas mixture comprising hydrogen (H 2 ) and carbon monoxide (CO),
wherein the bimetallic supported catalyst comprises 8 to 16 weight percent (wt. %) nickel and 4 wt. % copper, each based on a total weight of the bimetallic supported catalyst,
wherein 90-92.5% of the methane and 90-95% of the CO 2 in the reactant gas mixture is converted to form the hydrogen (H 2 ) and carbon monoxide (CO) in the product gas mixture over 6 hours of the contacting.

2. The method of claim 1 , wherein the porous catalyst support has a molar ratio of aluminum oxide to magnesium oxide of 1:1.05 to 1:4.

3. The method of claim 2 , wherein the porous catalyst support has a molar ratio of aluminum oxide to magnesium oxide of 1:1.75 to 1:2.25.

4. The method of claim 1 , wherein the bimetallic supported catalyst has a Brunner-Emmett-Teller (BET) surface area of 5 to 55 meter square per gram (m 2 /g).

5. The method of claim 1 , wherein the bimetallic supported catalyst has a mean pore size of 10 to 43 nanometer (nm) and a mean pore volume of 0.15 to 0.37 centimeter cube per gram (cm 3 /g).

6. The method of claim 1 , wherein the bimetallic catalyst is present as nanoparticles comprising nickel and copper.

7. The method of claim 6 , wherein the nanoparticles have a weight ratio of nickel to copper of 6:1 to 1.5:1.

8. The method of claim 7 , wherein the nanoparticles have a weight ratio of nickel to copper of 3.5:1 to 2.5:1.

9. The method of claim 6 , wherein the nanoparticles have a mean particle size of 15 to 75 nm.

10. The method of claim 1 , wherein the reactant gas mixture has a molar ratio of methane to carbon dioxide of 0.9:1 to 1.5:1.

11. The method of claim 10 , wherein the reactant gas mixture has a molar ratio of methane to carbon dioxide of 1.10:1 to 1.30:1.

12. The method of claim 1 , wherein the product gas mixture has a molar ratio of hydrogen to carbon monoxide of 0.90:1 to 1.1:1.

13. The method of claim 1 , wherein the reactant gas mixture is substantially free of water (H 2 O).

14. The method of claim 1 , wherein the contacting takes place in a reactor,
wherein the reactor comprises a tubular member having a square cross section,
wherein the tubular member comprises:
a catalytic bed;
an inlet;
an outlet; and
a furnace,

wherein the catalytic bed is configured to hold the bimetallic supported catalyst,
wherein the furnace comprises a plurality of heating coils attached to an inner surface of the furnace, wherein the plurality of heating coils heat the catalytic bed, and
wherein the tubular member is configured to have the reactant gas mixture enter through the inlet, pass over the catalytic bed with the bimetallic supported catalyst, and then collecting the product gas mixture through the outlet.

15. The method of claim 14 , wherein the bimetallic catalyst is in the form of nanoparticles, and the nanoparticles are Janus particles having a nickel side and a copper side.

16. The method of claim 14 , wherein the contacting is for 6 hours, the temperature is 800° C., and a molar ratio of methane to carbon dioxide in the reactant gas mixture is 1:1, and
wherein the bimetallic supported catalyst comprises 12 wt. % nickel based on a total weight of the bimetallic supported catalyst.

17. The method of claim 16 , wherein the porous catalyst support has a molar ratio of aluminum oxide to magnesium oxide of 1:2.

Assignees

• Univ King Abdulaziz

Inventors

• Mehedi Ibrahim Mustafa
• Abdullah Bawadi
• Yusuf Mohammad
• Al-Saggaf Ubaid M
• Al-Saggaf Ahmed Ubaid

Classifications

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J35/77

  Compounds characterised by their crystallite size · CPC title

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/45

  Nanoparticles · CPC title

• B01J2235/00

  Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties · CPC title