Nano-engineered catalysts for dry reforming of methane

Patent metadata

Field	Value
Publication number	US-2018353942-A1
Application number	US-201816007395-A
Country	US
Kind code	A1
Filing date	Jun 13, 2018
Priority date	Jun 13, 2017
Publication date	Dec 13, 2018
Grant date	—

Abstract

Catalysts and processing useful in the dry reforming of methane (DRM) are provided. Catalyst are composed of nickel (Ni) nanoparticles supported on a hollow fiber substrate, such as an α-Al 2 O 3 hollow fiber. The nickel (Ni) nanoparticles can be deposited onto the hollow fiber substrate support by atomic layer deposition. If desired, one or more layers of an overcoat of a promoter can be applied to increase catalyst performance such as in the reforming of methane.

First claim

What is claimed includes:

1 . A catalyst comprising nickel (Ni) nanoparticles supported on a hollow fiber substrate.

2 . The catalyst of claim 1 wherein the hollow fiber substrate comprises alumina.

3 . The catalyst of claim 1 wherein the hollow fiber substrate comprises α-Al 2 O 3 .

4 . The catalyst of claim 1 wherein the nickel (Ni) nanoparticles are 2-6 nm in size.

5 . The catalyst of claim 1 wherein the nickel (Ni) nanoparticles are deposited onto the hollow fiber substrate by atomic layer deposition.

6 . The catalyst of claim 1 additionally comprising an overcoat of a promoter to increase catalyst performance in reforming of methane, wherein the promoter is selected from the group consisting of Al 2 O 3 , CeO 2 , CaO and La 2 O 3 .

7 . The catalyst of claim 1 additionally comprising an alumina ALD overcoat as a promoter to increase catalyst performance in reforming of methane.

8 . The catalyst of claim 7 comprising multiple cycles of Al 2 O 3 ALD overcoat.

9 . The catalyst of claim 1 wherein the nickel (Ni) nanoparticles are nanoparticles selected from the group consisting of Ni+Co bimetallic nanoparticles, Ni+Pt bimetallic nanoparticles, and only nickel nanoparticles.

10 . The catalyst of claim 1 wherein the nickel (Ni) nanoparticles are neat nickel nanoparticles.

11 . A process for reforming methane, the process comprising:
contacting methane and carbon dioxide in the presence of the catalyst of claim 1 .

12 . A process for dry reforming methane, the process comprising:
introducing methane and carbon dioxide into a reactor containing a packed bed of a plurality of hollow fiber substrate supports carrying nickel (Ni) nanoparticles.

13 . The process of claim 12 wherein the hollow fiber substrate support comprise α-Al 2 O 3 .

14 . The process of claim 12 wherein the nickel (Ni) nanoparticles are 2-6 nm in size.

15 . The process of claim 12 wherein the nickel (Ni) nanoparticles are deposited onto α-Al 2 O 3 hollow fiber substrate supports by atomic layer deposition.

16 . The process of claim 15 wherein the α-Al 2 O 3 hollow fiber supports carrying nickel (Ni) nanoparticles include an overcoat of a promoter to increase catalyst performance in reforming of methane, wherein the promoter is selected from the group consisting of Al 2 O 3 , CeO 2 , CaO and La 2 O 3 .

17 . The process of claim 12 wherein the α-Al 2 O 3 hollow fiber supports carrying nickel (Ni) nanoparticles include an alumina ALD overcoat as a promoter to increase catalyst performance in reforming of methane.

18 . The process of claim 12 wherein the dry reforming produces syngas having H 2 /CO ratio of no more than 0.95.

19 . The process of claim 12 wherein the dry reforming produces syngas having H 2 /CO ratio in a range of 0.7 to 0.95.

20 . The process of claim 12 wherein the nickel (Ni) nanoparticles are nanoparticles selected from the group consisting of Ni+Co bimetallic nanoparticles, Ni+Pt bimetallic nanoparticles, and only nickel nanoparticles.

21 . The process of claim 12 wherein the nickel (Ni) nanoparticles are neat nickel nanoparticles.

22 . A method for producing a catalyst for dry reforming methane, the method comprising:
depositing nickel (Ni) nanoparticles onto a hollow fiber substrate support by atomic layer deposition.

23 . The method of claim 22 wherein the nickel (Ni) nanoparticles are 2-6 nm in size.

24 . The method of claim 22 wherein the hollow fiber substrate support comprises α-Al 2 O 3 .

25 . The method of claim 24 additionally comprising applying by atomic layer deposition at least one layer of a metal oxide coating over the nickel (Ni) nanoparticles on the α-Al 2 O 3 hollow fiber substrate support, the metal oxide coating increasing catalyst performance in reforming of methane.

26 . The method of claim 22 wherein the nickel (Ni) nanoparticles are neat nickel nanoparticles.

Assignees

• Liang Xinhua
• Shang Zeyu
• Li Shiguang
• Gas Technology Inst
• Univ Missouri

Inventors

• Liang Xinhua
• Shang Zeyu
• Li Shiguang

Classifications

• B01J23/78

  with alkali- or alkaline earth metals · CPC title

• B01J35/0006

  Operations & Transport · mapped topic

• C01B3/40

  characterised by the catalyst · CPC title

• B01J23/892 Primary

  Nickel and noble metals · CPC title

• C01B2203/0238

  the reforming step being a carbon dioxide reforming step · CPC title