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 showed CH₄ conversion >95%, H₂/CO ratio in the range of 0.7-1.0, and CH₄ reforming rate as high as 2,500 L/h/g_Ni at 850 ºC and pressure of 15-25 psia. The Ni-based ALD catalyst also showed good stability in DRM reaction during a 200-hour continuous operation at 850°C. This is due to a strong bonding between the nanoparticles and substrates since the Ni nanoparticles 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.