NiO-Ni-Al2O3(γ) Nanocatalyst by Pulse Electrocodeposition Over Ni Open-cell Foam for Methane Reforming

Document Type : Original Article

Authors

1 a Department of Materials Science and Nanotechnology, School of Science and Engineering, Sharif University of Technology, International Campus-Kish Island, Iran

2 Department of Materials Science and Engineering, Sharif University of Technology, Azadi Ave., Tehran, Iran

3 Centre for Advanced Coating Technologies, Faculty of Applied Science & Engineering, University of Toronto, 5 King’s College Road, Toronto, Ontario, M5S 3G8, Canada

Abstract

Global warming persuades researchers to improve the effectiveness of renewable energy technologies, such as H2 production by methane steam reforming (MSR) an endothermic process. Herein, a nanocatalyst based on open-cell nickel foam 40 (pore per inch) with high thermal conductivity was prepared. The nanocatalyst was synthesized with a chemical stepwise synthesis approach, chemical pre-treatment, pulsed electrocodeposition of Ni-Al2O3(γ) nanoparticles, and calcination.  Measurements of thermal diffusivity(α) with flash xenon technique gained 4.41×10-6 m2s-1 and values of specific heat capacity, Cp, by differential scanning calorimetry (DSC) and thermal conductivity(λ) enhanced by 65% in temperature range of 150 to 550°C in Ni-alumina(γ) foam nanocatalyst. Furthermore, characterization and tests for comparing nickel foam and Ni-alumina(γ) foam indicated that the hardness improved from 145 Vickers hardness (HV) to 547 HV and compression strength increased from 1.1 MPa to 5MPa and specific surface area (SBET) from 1.48 m2g-1 to 48 m2g-1.  XRD (x-ray diffraction) analysis showed NiO and NiAl2O4 in the structure. The interface between the catalytic component (NiAl2O4), and nickel affected the catalytic ability for MSR, and the efficiency gained at low tempreture 500 °C was the same as reported at 720°C by other investigations.

Graphical Abstract

NiO-Ni-Al2O3(γ) Nanocatalyst by Pulse Electrocodeposition Over Ni Open-cell Foam for Methane Reforming

Keywords

Main Subjects


  1. Acar, C. and Dincer, I., "Review and evaluation of hydrogen production options for better environment", Journal of Cleaner Production, Vol. 218, (2019), 835-849. https://doi.org/10.1016/j.jclepro.2019.02.046
  2. Etminan, A. and Sadrnezhaad, S., "A two step microwave-assisted coke resistant mesoporous ni-co catalyst for methane steam reforming", Fuel, Vol. 317, (2022), 122411. https://doi.org/10.1016/j.fuel.2021.122411
  3. Hosseini, Z., Mollazadeh Beidokhti, S., Vahdati khaki, J. and Pourabdoli, M., "Preparation of porous alumina/nano-nickel composite by gel casting and carbothermic reduction", International Journal of Engineering, Transactions A: Basics, Vol. 35, No. 1, (2022), 220-227.DOI:10.5829/IJE.2022.35.01A.21
  4. Tribalis, A., Panagiotou, G.D., Bourikas, K., Sygellou, L., Kennou, S., Ladas, S., Lycourghiotis, A. and Kordulis, C., "Ni catalysts supported on modified alumina for diesel steam reforming", Catalysts, Vol. 6, No. 1, (2016), 11. https://doi.org/10.3390/catal6010011
  5. Silva, C.K.S., Baston, E.P., Melgar, L.Z. and Bellido, J.D.A., "Ni/al2o3-la2o3 catalysts synthesized by a one-step polymerization method applied to the dry reforming of methane: Effect of precursor structures of nickel, perovskite and spinel", Reaction Kinetics Mechanisms and Catalysis, Vol. 128, No. 1, (2019), 251-269. DOI:10.1007/s11144-019-01644-3
  6. Naeem, M.A., Al-Fatesh, A.S., Fakeeha, A.H. and Abasaeed, A.E., "Hydrogen production from methane dry reforming over nickel-based nanocatalysts using surfactant-assisted or polyol method", International Journal of Hydrogen Energy, Vol. 39, No. 30, (2014), 17009-17023. https://doi.org/10.1016/j.ijhydene.2014.08.090
  7. Pashchenko, D., "Experimental investigation of reforming and flow characteristics of a steam methane reformer filled with nickel catalyst of various shapes", Energy Conversion and Management, Vol. 185, (2019), 465-472. https://doi.org/10.1016/j.enconman.2019.01.103
  8. Rohani, A., Allahkaram, L. and Omidvar, A., "Effect of nickel-alumina nanoparticle catalyst on the performance of methane steam reforming process", American Journal of Nanoscience and Nanotechnology, Vol. 1, No. 3, (2013), 74-78. DOI:10.11648/j.nano.20130103.13
  9. Meloni, E., Martino, M. and Palma, V., "A short review on ni based catalysts and related engineering issues for methane steam reforming", Catalysts, Vol. 10, No. 3, (2020), 352. https://doi.org/10.3390/catal10030352
  10. Baharudin, L. and Watson, M.J., "Monolithic substrate support catalyst design considerations for steam methane reforming operation", Reviews in Chemical Engineering, Vol. 34, No. 4, (2018), 481-501. https://doi.org/10.1515/revce-2016-0048
  11. Maleki, B., Natheghi, H., Tayebee, R., Alinezhad, H., Amiri, A., Hossieni, S.A. and Nouri, S.M.M., "Synthesis and characterization of nanorod magnetic co–fe mixed oxides and its catalytic behavior towards one-pot synthesis of polysubstituted pyridine derivatives", Polycyclic Aromatic Compounds, Vol. 40, No. 3, (2020), 633-643. https://doi.org/10.1080/10406638.2018.1469519
  12. Tsiotsias, A.I., Charisiou, N.D., Yentekakis, I.V. and Goula, M.A., "Bimetallic ni-based catalysts for CO2 methanation: A review", Nanomaterials, Vol. 11, No. 1, (2020), 28. https://doi.org/10.3390/nano11010028
  13. Aramouni, N.A.K., Touma, J.G., Tarboush, B.A., Zeaiter, J. and Ahmad, M.N., "Catalyst design for dry reforming of methane: Analysis review", Renewable and Sustainable Energy Reviews, Vol. 82, (2018), 2570-2585. https://doi.org/10.1016/j.rser.2017.09.076
  14. Barzegari, F., Kazemeini, M., Farhadi, F., Rezaei, M. and Keshavarz, A., "Preparation of mesoporous nanostructure nio–mgo–sio2 catalysts for syngas production via propane steam reforming", International Journal of Hydrogen Energy, Vol. 45, No. 11, (2020), 6604-6620. https://doi.org/10.1016/j.ijhydene.2020.01.007
  15. Bianchi, E., Heidig, T., Visconti, C.G., Groppi, G., Freund, H. and Tronconi, E., "Heat transfer properties of metal foam supports for structured catalysts: Wall heat transfer coefficient", Catalysis Today, Vol. 216, (2013), 121-134. https://doi.org/10.1016/j.cattod.2013.06.019
  16. Zafardoagoo, M. and Sadrnezhaad, S.K., "Synthesis of porous nickel foam based on electroless plating on polymeric substrate and electrodeposition", Journal of Advanced Materials and Technologies, Vol. 11, No. 1, (2022), 69-79. https://doi.org/10.30501/jamt.2022.325426.1210
  17. Kulshreshtha, A. and Dhakad, S.K., "Preparation of metal foam by different methods: A review", Materials Today: Proceedings, Vol. 26, (2020), 1784-1790. https://doi.org/10.1016/j.matpr.2020.02.375
  18. Cimino, S., Cepollaro, E.M., Lisi, L., Fasolin, S., Musiani, M. and Vázquez-Gómez, L., "Ru/ce/ni metal foams as structured catalysts for the methanation of CO2", Catalysts, Vol. 11, No. 1, (2021), 13. https://doi.org/10.3390/catal11010013
  19. Settar, A., Abboudi, S. and Lebaal, N., "Effect of inert metal foam matrices on hydrogen production intensification of methane steam reforming process in wall-coated reformer", International Journal of Hydrogen Energy, Vol. 43, No. 27, (2018), 12386-12397. https://doi.org/10.1016/j.ijhydene.2018.04.215
  20. Ashraf, M.A., Sanz, O., Montes, M. and Specchia, S., "Insights into the effect of catalyst loading on methane steam reforming and controlling regime for metallic catalytic monoliths", International Journal of Hydrogen Energy, Vol. 43, No. 26, (2018), 11778-11792. https://doi.org/10.1016/j.ijhydene.2018.04.126
  21. Gokon, N., Nakamura, S., Matsubara, K. and Kodama, T., "Carbonate molten-salt absorber/reformer: Heating and steam reforming performance of reactor tubes", Energy Procedia, Vol. 49, (2014), 1940-1949. https://doi.org/10.1016/j.egypro.2014.03.206
  22. Palma, V., Ricca, A., Martino, M. and Meloni, E., "Innovative structured catalytic systems for methane steam reforming intensification", Chemical Engineering and Processing-Process Intensification, Vol. 120, (2017), 207-215. https://doi.org/10.1016/j.cep.2017.07.012
  23. Basile, F., Benito, P., Del Gallo, P., Fornasari, G., Gary, D., Rosetti, V., Scavetta, E., Tonelli, D. and Vaccari, A., "Highly conductive ni steam reforming catalysts prepared by electrodeposition", Chemical Communications, No. 25, (2008), 2917-2919. https://doi.org/10.1039/B801645C
  24. Cheri, A. and Nebbali, R., "Numerical analysis on autothermal steam methane reforming: Effects of catalysts arrangement and metal foam insertion", International Journal of Hydrogen Energy, Vol. 44, No. 39, (2019), 22455-22466. DOI:10.1016/j.ijhydene.2018.12.203
  25. Chen, J., "Mechanical properties of electrolyte jet electrodeposited nickel foam", Journal of Engineering Science and Technology Review, Vol. 6, No. 2, (2013), 53-56. DOI:10.25103/jestr.062.12
  26. Li, Y.-g., Wei, Y.-h., Hou, L.-f., Guo, C.-l. and Yang, S.-q., "Fabrication and compressive behaviour of an aluminium foam composite", Journal of Alloys and Compounds, Vol. 649, (2015), 76-81. https://doi.org/10.1016/j.jallcom.2015.07.049
  27. Wang, X., Zhou, Y., Li, J. and Li, H., "Uniaxial compression mechanical properties of foam nickel/iron-epoxy interpenetrating phase composites", Materials, Vol. 14, No. 13, (2021), 3523. https://doi.org/10.3390/ma14133523
  28. Parveez, B., Jamal, N.A., Anuar, H., Ahmad, Y., Aabid, A. and Baig, M., "Microstructure and mechanical properties of metal foams fabricated via melt foaming and powder metallurgy technique: A review", Materials, Vol. 15, No. 15, (2022). https://doi.org/10.3390/ma15155302
  29. Liu, J., Zhang, L., Liu, S., Han, Z. and Dong, Z., "Effect of si content on microstructure and compressive properties of open-cell mg composite foams reinforced by in-situ mg2si compounds", Materials Characterization, Vol. 159, (2020), 110045. https://doi.org/10.1016/j.matchar.2019.110045
  30. Chen, J., Zhang, P., Cheng, Y. and Liu, J., "On the crushing response of the functionally graded metallic foams based on 3d voronoi model", Thin-Walled Structures, Vol. 157, (2020), 107085. https://doi.org/10.1016/j.tws.2020.107085
  31. Somwanshi, S.B., Somvanshi, S.B. and Kharat, P.B., "Nanocatalyst: A brief review on synthesis to applications", in Journal of Physics: Conference Series, IOP Publishing. Vol. 1644, No. 1, (2020), 012046. DOI:10.1088/1742-6596/1644/1/012046
  32. Ren, Z., Zhang, J., Bai, Y., Wang, J., Chen, H., Hao, Q. and Ma, X., "Unsupported nickel catalyst prepared from nickel foam for methane decomposition and recycling the carbon deposited spent catalyst", International Journal of Hydrogen Energy, Vol. 46, No. 42, (2021), 21853-21865. https://doi.org/10.1016/j.ijhydene.2021.04.026
  33. Chai, R., Li, Y., Zhang, Q., Zhao, G., Liu, Y. and Lu, Y., "Monolithic ni–mox/ni-foam (m= al, zr or y) catalysts with enhanced heat/mass transfer for energy-efficient catalytic oxy-methane reforming", Catalysis Communications, Vol. 70, (2015), 1-5. https://doi.org/10.1016/j.catcom.2015.07.007
  34. Pegios, N., Schroer, G., Rahimi, K., Palkovits, R. and Simeonov, K., "Design of modular ni-foam based catalysts for dry reforming of methane", Catalysis Science & Technology, Vol. 6, No. 16, (2016), 6372-6380. http://dx.doi.org/10.1039/C6CY00282J
  35. Lajevardi, S.A., Shahrabi, T. and Szpunar, J.A., "Synthesis of functionally graded nano Al2O3–Ni composite coating by pulse electrodeposition", Applied Surface Science, Vol. 279, (2013), 180-188. https://doi.org/10.1016/j.apsusc.2013.04.067
  36. Jegan, A. and Venkatesan, R., "Characterization and optimization of pulse electrodeposition of Ni/nano- Al2O3 composite coatings", International Journal of Minerals, Metallurgy, and Materials, Vol. 20, No. 5, (2013), 479-485. https://doi.org/10.1007/s12613-013-0754-z
  37. Gül, H., Kılıç, F., Aslan, S., Alp, A. and Akbulut, H., "Characteristics of electro-co-deposited Ni– Al2O3 nano-particle reinforced metal matrix composite (mmc) coatings", Wear, Vol. 267, No. 5-8, (2009), 976-990. https://doi.org/10.1016/j.wear.2008.12.022
  38. Mirzamohammadi, S., Khorsand, H., Aliofkhazraei, M. and Shtansky, D., "Effect of carbamide concentration on electrodeposition and tribological properties of Al2O3 nanoparticle reinforced nickel nanocomposite coatings", Tribology International, Vol. 117, (2018), 68-77. https://doi.org/10.1016/j.triboint.2017.08.003
  39. Karimi, E.Z., Barzegar, F., Moloodi, A. and Zolfaghari, R., "Hardness and compressive properties of open-cell nickel foam reinforced by nano-sic particles", Metallurgical and Materials Transactions B-Process Metallurgy and Materials Processing Science, Vol. 52, No. 5, (2021), 3439-3446. DOI:10.1007/s11663-021-02273-9
  40. Kolaczkowski, S.T., Awdry, S., Smith, T., Thomas, D., Torkuhl, L. and Kolvenbach, R., "Potential for metal foams to act as structured catalyst supports in fixed-bed reactors", Catalysis Today, Vol. 273, (2016), 221-233. https://doi.org/10.1016/j.cattod.2016.03.047
  41. Syamsuir, S., Soegijono, B., Yudanto, S.D., Basori, B., Ajiriyanto, M.K., Nanto, D. and Susetyo, F.B., "Electrolyte temperature dependency of electrodeposited nickel in sulfate solution on the hardness and corrosion behaviors", International Journal of Engineering, Transactions C: Aspects, Vol. 36, No. 6, (2023), 1193-1200. DOI:10.5829/ije.2023.36.06c.18
  42. Oveisi, H. and Geramipour, T., "High mechanical performance alumina-reinforced aluminum nanocomposite metal foam produced by powder metallurgy: Fabrication, microstructure characterization, and mechanical properties", Materials Research Express, Vol. 6, No. 12, (2020), 1250c1252.DOI:10.1088/2053-1591/ab608b
  43. Kim, S., Tserengombo, B., Choi, S.H., Noh, J., Huh, S., Choi, B., Chung, H., Kim, J. and Jeong, H., "Experimental investigation of heat transfer coefficient with Al2O3 nanofluid chock in small diameter tubes", Applied Thermal Engineering, Vol. 146, No., (2019), 346-355. DOI:10.1016/j.applthermaleng.2018.10.001
  44. Sharifi, Z., Asgari, G. and Seid-Mohammadi, A., "Sonocatalytic degradation of p-chlorophenol by nanoscale zero-valent copper activated persulfate under ultrasonic irradiation in aqueous solutions", International Journal of Engineering, Transactions C: Aspects, Vol. 33, No. 6, (2020), 1061-1069.DOI:10.5829/IJE.2020.33.06C.03
  45. Kirgizov, A.Y., Il'yasov, I.R., Laskin, A.I. and Lamberov, A.A., "An investigation of surface transformations of nickel highly porous cellular material with an applied alumina layer during its synthesis", Protection of Metals and Physical Chemistry of Surfaces, Vol. 54, No. 5, (2018), 788-794. DOI:10.1134/s2070205118040068
  46. Jiao, L., Xiao, H., Wang, Q. and Sun, J., "Thermal degradation characteristics of rigid polyurethane foam and the volatile products analysis with tg-ftir-ms", Polymer Degradation and Stability, Vol. 98, No. 12, (2013), 2687-2696. https://doi.org/10.1016/j.polymdegradstab.2013.09.032
  47. Nikolić, V., Kamberović, Ž., Korać, M., Anđić, Z., Mihajlović, A. and Uljarević, J.B., "Nickel-based catalysts: Dependence of properties on nickel loading and modification with palladium", Hemijska industrija, Vol. 70, No. 2, (2016), 137-142. DOI:10.2298/HEMIND140928090N
  48. Qiu, P., WU, G.-h., SUN, D.-l., XIU, Z.-y., ZHANG, Q. and HU, Z.-l., "Compressive property and energy absorption characteristic of 3d open-cell Ni–Cr–Fe alloy foams under quasi-static conditions", Transactions of Nonferrous Metals Society of China, Vol. 22, (2012), 566-572. https://doi.org/10.1016/S1003-6326(12)61762-2
  49. Luo, G., Xue, P. and Li, Y.L., "Experimental investigation on the yield behavior of metal foam under shear-compression combined loading", Science China-Technological Sciences, Vol. 64, No. 7, (2021), 1412-1422. DOI:10.1007/s11431-020-1786-6
  50. Wan, T., Liu, Y., Zhou, C., Chen, X. and Li, Y., "Fabrication, properties, and applications of open-cell aluminum foams: A review", Journal of Materials Science & Technology, Vol. 62, (2021), 11-24. https://doi.org/10.1016/j.jmst.2020.05.039
  51. Mishra, R., Militky, J. and Venkataraman, M., 7 - nanoporous materials, in Nanotechnology in textiles, R. Mishra and J. Militky, Editors. 2019, Woodhead Publishing. 311-353. https://doi.org/10.1016/B978-0-08-102609-0.00007-9
  52. Speight, J.G., 3 - unconventional gas, in Natural gas (second edition), J.G. Speight, Editor. 2019, Gulf Professional Publishing: Boston. 59-98. https://doi.org/10.1016/B978-0-12-809570-6.00003-5
  53. Feng, L., Ren, Y.-Y., Zhang, Y.-H., Wang, S. and Li, L., "Direct correlations among the grain size, texture, and indentation behavior of nanocrystalline nickel coatings", Metals, Vol. 9, No. 2, (2019), 188. https://doi.org/10.3390/met9020188
  54. Sajjadnejad, M., Omidvar, H. and Javanbakht, M., "Influence of pulse operational parameters on electrodeposition, morphology and microstructure of ni/nanodiamond composite coatings", International Journal of Electrochemical Science, Vol. 12, No. 5, (2017), 3635-3651. https://doi.org/10.20964/2017.05.5
  55. Shafiee, Z., Bahrololoom, M.E. and Hashemi, B., "Electrodeposition of nanocrystalline Ni/Ni– Al2O3 nanocomposite modulated multilayer coatings", Materials & Design, Vol. 108, (2016), 19-26. https://doi.org/10.1016/j.matdes.2016.06.018
  56. Tanksale, A., Beltramini, J., Dumesic, J. and Lu, G.Q., "Effect of pt and pd promoter on ni supported catalysts—a tpr/tpo/tpd and microcalorimetry study", Journal of Catalysis, Vol. 258, No. 2, (2008), 366-377. https://doi.org/10.1016/j.jcat.2008.06.024
  57. Daroughegi, R., Meshkani, F. and Rezaei, M., "Enhanced low-temperature activity of CO2 methanation over ceria-promoted ni- Al2O3 nanocatalyst", Chemical Engineering Science, Vol. 230, (2021).DOI:10.1016/j.ces.2020.116194
  58. Navarro, M.V., Plou, J., Lopez, J.M., Grasa, G. and Murillo, R., "Effect of oxidation-reduction cycles on steam-methane reforming kinetics over a nickel-based catalyst", International Journal of Hydrogen Energy, Vol. 44, No. 25, (2019), 12617-12627. DOI:10.1016/j.ijhydene.2018.12.056