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Article history: Catalytic plate reactors offer many advantages over conventional reactors, including a major reduction in size
Received 9 July 2010 and much better temperature control. This study examines the characteristics of thin catalyst coats prepared
Received in revised form 14 March 2011 by the sol–gel method and calcined at different conditions. Employing the catalyst as a thin layer (b 100 μm)
Accepted 9 April 2011
on the surface of plate reactors reduces mass and heat transfer limitations compared with pellet catalysts and
Available online 29 June 2011
can improve the effectiveness factor. A sol–gel of Ni/Al2O3 catalyst, with good rheological properties and good
Keywords:
adherence onto stainless steel substrate, was prepared and characterized. The effects of calcination
Catalytic plate reactor temperature, nickel content and calcination environment on the catalyst properties were investigated. The
Thin layer catalysts results revealed that the highest catalyst surface area was obtained at 400 °C for all calcined coatings. The
Catalytic coating presence of nitrogen gas during drying and calcining seemed to increase the catalyst surface areas and
Sol–gel improve its adherence properties. Rheological evaluation of the prepared coats proved to be an effective tool
in characterizing the thin coatings. The Ni/Al2O3 catalyst exhibited high activity and achieved more than 80%
conversion for steam reforming of methane. The reactions were not diffusion limited based on the values of
activation energy.
© 2011 Elsevier B.V. All rights reserved.
0378-3820/$ – see front matter © 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.fuproc.2011.04.020
M.A. Al-Nakoua et al. / Fuel Processing Technology 92 (2011) 1836–1841 1837
Exothermic
Exothermic catalyst
process gas
Heat Plate
Endothermic
catalyst
Endothermic
process gas
plate reactor is not as scale sensitive as conventional reactors and is expected that the starting Ni fraction will remain the same after the
compactness and low weight also make it attractive for automotive reduction process.
applications. Hydrogen is a clean burning fuel and can be directly
burnt in an internal combustion engine or electrochemically trans- 2.2. Surface area and pore size measurements
formed to electricity in a fuel cell. Neither of these methods produces
carbon dioxide nor monoxide [7]. Pure alumina and three Ni/Al2O3 sol–gel recipes (25, 50 and 75% Ni)
For many years nickel has been regarded as the most suitable were poured into crucibles, dried at 100 °C and calcined at temperatures
metal for steam reforming of methane. Other metals can be ranging from 300 to 700 °C. The surface area and pore size were
employed; for example cobalt, platinum, palladium, iridium, ruthe- determined by the Accelerated Surface Area and Porosity system (ASAP
nium and rhodium. Some of these precious metals are more active per 2010, Micromeretics, US) fitted with an optional high stability 1 Torr
unit mass than nickel but are more expensive and nickel is effectively (1 mmHg (0 °C)) pressure transducer employing the static volumetric
active to enable suitable catalysts to be produced economically. method. The samples were degassed at 200 °C on the degas ports of the
Therefore, various metals that modify the active phase can be added to analyzer under reduced pressure of 10− 5 Torr (10− 5 mmHg (0 °C)).
increase the practical life and the stability of the nickel supported The BET surface area and pore size were then determined through the
catalysts. adsorption of nitrogen (purity 99.999%) at −196 °C.
Preparation techniques are crucial in developing an active,
selective, stable and durable catalyst. Although the sol–gel technique 2.3. Coating of the stainless steel shims
has been adopted for stainless steel substrate and micro-channel
reactors coatings [8–11], there have been limited studies on the Stainless steel shims (thin sheets) were coated by careful dipping
characterization and testing of catalyst coats prepared by the sol–gel into the sol jar using tweezers; the bottom face of the shims was
method. Recently, Mirzaei, et al. [12] investigated the preparation and cleaned using tissues. The shims, which were 35 mm in length, 35 mm
characterization of sol–gel catalysts. However, their study focused on in width and 2 mm in thickness, were dried in a muffle furnace at
using catalyst powder in a fixed bed reactor for Fisher–Tropsch 100 °C. The shims were recoated for a second and a third time and
reactions. To the best of the authors' knowledge there have been no then calcined at 400 °C. The topology of calcined Ni/Al2O3 catalysts
reports in the open literature on the testing of sol–gel coats in (25, 50 and 75% Ni) coatings was examined visually, by Scanning
important potential applications such as methane steam reforming. Electron Microscope (SEM), and by Energy Dispersive X-ray (EDX).
The main objective of the present study, therefore, was to investigate The EDX analysis was carried out using Jeol, Model JSM-5600.
the preparation and characterization of sol–gel nickel–alumina
catalyst coatings, and to evaluate their potential in reducing mass 2.4. Rheological measurements
transfer limitations in methane steam reforming.
Rheological properties of the prepared sol–gels were measured
with a Rheolab QC viscometer from Anton Paar, Germany. Concentric
2. Experimental methods cylinder measuring system used is according to ISO 3219 and DIN
53019. The shear stress (τ) of the samples was measured as a function
2.1. Synthesis of sol–gel of shear rate (γ̇) at a constant temperature. All rheological tests were
performed at 25 °C. The measurements were carried out with
Catalysts were prepared by dispersing ‘Disperal’ alumina supplied increasing (forward measurements) and decreasing (backward
by Sasol, Germany [13] in a solution of dilute nitric acid (1 wt.%, measurements) shear rates.
0.11 M) to give 5 wt.% alumina sol–gel. Since the powder contains 78%
of alumina this was taken into account when making up the sol–gel. 2.5. Catalyst testing
The alumina was poured into a 100 ml measuring beaker containing
the acid then the sol gel was mixed for 10 to 15 min. A glass propeller, A plate reactor (see Fig. 2) was specially designed and fabricated
with a spinning speed of approximately 200 rpm provided by rotating from stainless steel to test the prepared catalyst coatings; the reactor
motor, was used for mixing. Nickel, as nitrates, was added to the external dimensions were 125 mm × 25 mm × 10 mm. The coats were
alumina sol–gel to give the desired nickel/alumina ratio. After applied on the walls of a longitudinal channel of 8 × 2 mm cross-
vigorous stirring at room temperature for about 30 min, the sol–gel section, giving a channel surface area of 25 cm2. The channel
was ready for testing or coating. The nickel fraction in the nickel/ dimension is similar to those in commercial compact reactors. The
alumina mixture was varied from 5 to 75 wt.%. Although the nickel reaction temperatures were measured along the length of the channel
will be oxidized during the calcination process, it will be reduced by using six thermocouples, their tips positioned at about 0.5 mm from
the addition of hydrogen before any methane reforming application. It the channel internal surface. The reactor was coated with catalyst by
1838 M.A. Al-Nakoua et al. / Fuel Processing Technology 92 (2011) 1836–1841
Reactor width
Channel 25 mm
width Reaction zone
8 mm
Thermocouple holes
forcing the sol–gel through the channel, blowing out the surplus and surface area is slightly higher in the presence of nitrogen stream for all
air-drying. The reactor was placed axially in a muffle furnace, which catalyst ratios. This is in agreement with results reported in literature
also preheated the feed to the reaction temperature. Multiple coats [10], which concluded that the presence of nitrogen stream is
were used to build up the desired catalyst weight and calcined in the constructive during drying and calcining process.
presence of nitrogen stream at the desired temperature. The reactor
was light enough to be weighed to ±1 mg, giving accuracy in the 3.2. Coating characterization
mass of catalyst of ±1%. After calcination, the catalysts were reduced
in-situ in a stream of hydrogen at 600 °C for at least 2 h; a small flow Most of the recipes adhered well to the substrate and flakes were
of hydrogen (about 1 l/h) was maintained throughout the experi- only observed at low nickel content (25% Ni). The SEM images of the
ments to prevent the metal from re-oxidation. calcined samples, which are shown in Fig. 5, indicate that less cracks
were observed for relatively higher nickel content (50% Ni). Three
3. Results and discussion coats of Ni (50%)/Al2O3 (50%) catalyst formed cracks with a width
about 5 μ and from 50 to 500 μ length (Fig. 5B). On other hand, three
3.1. BET surface area and pore size distribution coats of Ni (25%)/Al2O3 (75%) catalyst formed cracks with a width
about 50 μ and infinite length where the cracks connected to each
The calcining temperature was varied from 300 to 700 °C. It is other, see Fig. 5A.
observed that the catalyst calcined at 400 °C has the highest surface Energy dispersive X-ray (EDX) analysis, equipped with SEM, were
area and well-defined pore size distribution for all catalyst ratios. The carried out on multiple and random points on the coated shims. The
results also revealed that increasing the metal (nickel) content results showed that the metal and support were evenly distributed
decreased the surface area as shown in Fig. 3. However, the results within the catalyst layer as clearly illustrated by Fig. 6 for two coatings
showed that the surface area and pore volume of the Ni/Al2O3 catalyst with different nickel contents. Iron, which appeared in the EDX
were much lower than those for pure alumina (Table 1). These effects analysis, was from the stainless steel substrate. An additional benefit
on the characteristic of alumina sol–gels when mixed with metal salt of using sol–gel method is that the quantity of active metal in the
solutions have been reported to be caused by an alteration in pH and catalyst is precisely known and is simple to adjust. This also provides a
ion (cation and anion) concentrations of the sol [8]. This affects the good dispersion of the metal in the calcined catalyst. The sol–gel
consistency of the sol–gel resulting in agglomeration and hence method put an end to the routine manner to coat the substrate with
decreasing the pore volume and surface areas of the calcined sol–gel the support, calcine, impregnate with active metal and then further
as shown in Table 1. The Effect of the presence of nitrogen gas during calcine.
drying and calcining on the catalyst surface area was also investigated.
The sol gel samples were dried at 100 °C and calcined at 400 °C with 3.3. Rheology of the sol–gel
and without nitrogen purge in tube furnace. The surface area results
are presented in Fig. 4 for different nickel contents and show that the The flow curves of sol–gel samples with different Ni content were
measured in the shear rate range of 10–1500 1/s. Fig. 7 shows the
250 apparent viscosity of 25% Ni and 50% Ni samples as a function of shear
0% Ni rate. Both samples exhibited shear thinning behavior. Viscosity of a
25% Ni
shear thinning material is dependent on the degree of the shear load
BET surface area (m 2/g)
200 50% Ni
75% Ni (shear rate), where the apparent viscosity decreases with increasing
load. For the sol–gel samples, the shear process can cause the particles
150 to be oriented into the flow direction. During this process, the
interactive forces between the particles are usually becoming weaker
100
Table 1
Surface area and pore volume for samples calcined at 400 °C.
50
Ni% BET Total pore Micropore Mesopore Pore Micropore
area volume volume, volume diameter volume
0 (m2/g) (cm3/g) (cm3/g) (cm3/g) A fraction
300 400 500 600 700 800
0 189.84 0.28 0.0027 0.28 59.57 0.0097
Temperature (oC) 25 142.05 0.22 0.0097 0.21 61.35 0.0447
50 106.11 0.28 0.0075 0.27 104.90 0.0269
75 64.29 0.19 0.0053 0.19 120.65 0.0273
Fig. 3. BET surface area versus calcination temperature for different Ni/Al2O3 ratios.
M.A. Al-Nakoua et al. / Fuel Processing Technology 92 (2011) 1836–1841 1839
210
N2 Purge
180 No Purge
BET surface area (m 2/g)
150
120
90
60
30
0 10 20 30 40 50 60 70 80
Amount of Ni (wt% )
Fig. 4. Effect of nitrogen purge on BET surface area for different nickel contents at
400 °C.
1000
B 25% Ni
50% Ni
Viscosity (mPa.s)
100
10
100 1000
Shear Rate (1/s)
Fig. 5. SEM images of three coats of catalyst calcined at 400 °C over a metal shim. A: Ni
(25%)/Al2O3 (75%); B: Ni (50%)/Al2O3 (50%). Fig. 7. Apparent viscosity of 25% Ni and 50% Ni samples as a function of shear rate.
1840 M.A. Al-Nakoua et al. / Fuel Processing Technology 92 (2011) 1836–1841
0.9 740
25% Ni
50% Ni 0.8 720
H-B Model
Shear Stress (Pa)
Temperature ( oC)
0.7 700
Conversion
0.6 680
0.5 660
10
0.4 640
Fig. 8. Flow curves of 25% Ni and 50% Ni samples fitted to Herschel–Bulkley model. Fig. 9. Conversion and average reactor temperature versus time over Ni(50%)/Al2O3
(50%) at 40 psig (276 kPa), catalyst loading 4.8 mg/cm2.
25% Ni sample. This led to less cracks for the latter, as illustrated by
Fig. 5B, since unstable coating lead to large shrinkage, surface cracking 140
and bulk material defects. Constant viscosity at high shear rate is
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