Development of Spherical Ni-Co/MgAlO Bimetallic Catalyst for CO2 Reforming of CH4

Carbon dioxide reforming, or drying reforming, of methane can now be used in new applications such as landfill gas utilization where CO and CH need to be converted to a mixture of CO and H, called synthesis gas or syn-gas. A novel Ni-Co/AlMgO bimetallic powder catalyst was developed in previous research for dry reforming of methane (DRM) process which can eliminate carbon deposition. But it is difficult242x to apply this loose-powder catalyst in industrial scale. The procedure of making spherical Ni-Co/AlMgOx bimetallic catalyst supported on BASF CSS-350 alumina balls (BASF Catalysts LLC) using impregnation method with different impregnation steps and calcination steps is explained in this thesis. For every batch of preparation, the concentration of metal solution was calculated based on different impregnation steps. BET (Brunauer-Emmett-Teller) analysis, compressive strength test, XANES (X-ray Absorption Near-Edge Structure) measurement and ICP-MS (Inductively Coupled Plasma Mass Spectrometry) analysis are conducted to understand the physical and chemical properties of the catalyst. It is found that both impregnation steps and calcination steps have great influence on the performance of the prepared catalyst samples. Among all the catalysts prepared, BF-4-0.25(MgNiCo)-C, which was made by using 4 impregnation-calcination cycles, shows the best activity and stability for 160 h time-on stream (TOS) under the reaction condition of 0.10 g catalyst loading, 750 oC, ambient pressure, GHSV=100,000 ml/gc·h, and CH4/CO2/N2 = 1/1/1. The CH4 conversion started at 66.7% and slowly dropped to 52.8% after 160 hours. I I BF-4-0.25(MgNiCo)-C spherical catalyst shows lower reaction rate compared to the loose powder format but shows compatible or higher activity to other two reported catalysts in similar compositions. Most importantly, it is a shaped catalyst ready for industrial use