(232c) Nano-Engineered Catalyst for the Utilization of CO2 in Dry Reforming to Produce Syngas

The objective of this study was to develop a novel catalytic reactor containing nano-engineered catalyst for the utilization of CO₂ (captured from coal-fired power plants) in dry reforming of methane (DRM) (CO₂ + CH₄ → 2 H₂ + 2 CO) to produce synthesis gas (syngas). The technology aims to reduce CO₂ emissions by developing beneficial uses for CO₂ from coal-fired power plants. It also offers an alternative to mitigate CO₂ emissions in areas where geologic storage may not be an optimal solution and/or utilization could significantly offset the costs of carbon capture and sequestration. 

The nano-engineered Ni-based catalyst was prepared by atomic layer deposition (ALD). The Ni particles were as small as ~2-4 nm. The nano-engineered catalyst supported on porous γ-Al₂O₃ particles showed extremely high methane reforming rates at different temperatures (1840 Lh^-1g_Ni^-1 at 850 °C, 1740 Lh^-1g_Ni^-1 at 800 °C, 1320 Lh^-1g_Ni^-1 at 750 °C). These are the highest DRM reaction rates reported to date as compared to data in the literature. The Ni-based ALD catalyst also showed good stability in DRM reaction during a 300-hour continuous operation at temperatures that ranged from 700°C to 850°C. The good stability is due to a strong bonding between the nanoparticles and substrates since the particles were chemically bonded to the substrate during the ALD process. The high thermal stability maintains high dispersion of Ni nanoparticles, which can inhibit coke formation, because their step edges are small enough to limit carbon nucleation and growth.