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Fuel Processing Technology 92 (2011) 1836–1841

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Fuel Processing Technology


j o u r n a l h o m e p a g e : w w w. e l s ev i e r. c o m / l o c a t e / f u p r o c

Characterization and testing of sol–gel catalysts prepared as thin layers in a


plate reactor
Mohamed A. Al-Nakoua, Muftah H. El-Naas ⁎, Basim Abu-Jdayil
Chemical and Petroleum Engineering Department, United Arab Emirates University, P.O. Box: 17555, Al Ain, United Arab Emirates

a r t i c l e i n f o a b s t r a c t

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.

1. Introduction exothermic and endothermic reaction on opposite sides of a plate


forming part of a heat exchanger was first proposed by Hunter and
Most chemical products in the world market are manufactured McGuire [2], has been highlighted by Ramshaw [3] for many years and
through heterogeneous catalytic processes. Reactors involving solid reviewed by Anxionnaz et al. [4]. It is illustrated in Fig. 1.
catalysts represent a crucial tool in the chemical industry, and the The use of sol–gel method for catalyst preparation has been
majority of reactors used in the gas–liquid processes contain catalysts described by Pajonk [5]. The method has several advantages such as a
either as stationary or moving particles of various shapes and sizes. well-defined pore size distribution, high purity control of reactants,
These conventional reactors have a number of recognized restrictions homogeneity, very large and controlled porosity combined with the
and disadvantages, including mass and heat transfer limitations, low ability to form large surface area. Moreover, the catalyst prepared by
specific surface area of the catalyst, high pressure drop and thermal sol–gel has high thermal stability and resistance to deactivation. High
instabilities (runaway) in stationary beds, or catalyst attrition and metal dispersions and thermal resistant catalysts can be accomplished
device erosion in slurry reactors [1]. There are numbers of reports by sol gel technique in the synthesis of supported metal catalyst, these
demonstrating that these limitations can be avoided by employing properties guide to maximizing support metal precursor interactions,
thin film catalyst using catalytic plate reactor methodology. The BET surface areas and support pore structure. The sol gel method may
advantages of catalytic plate reactor designs over conventional use a variety of supports rather than alumina and silica to prepare
reactors include excellent heat transfer characteristics and minimal mixed oxide supports [6].
intra-catalyst diffusion resistance. The heat transfer mechanism One of the most important potential applications of thin catalyst
within a catalytic plate reactor is via conduction through the plate coats is methane-steam reforming in a plate reactor according to the
separating alternate process channels; this heat transfer rate is largely following reactions:
independent of the process gas superficial velocity. By utilizing the
catalytic heat exchanger plate reactor, a reduction in size of CH4 + H2 O↔CO + 3H2 0
ΔH298k = + 206:1kJ = mol ð1Þ
equipment by two orders of magnitude is possible, even if there is
no improvement in the process catalyst. This concept, coupling an CO + H2 O↔CO2 + H2
0
ΔH298k = −41:0kJ = mol ð2Þ

This is a particularly attractive target for the application of plate


⁎ Corresponding author. Fax: + 971 3 762 4262. reactors as there is a huge potential application in the distributed
E-mail address: muftah@uaeu.ac.ae (M.H. El-Naas). production of small quantities of hydrogen for fuel cells. The cost of a

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

Fig. 1. A schematic diagram of pair of adjacent channels in a catalytic plate reactor.

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

Channel length 125 mm

Reactor width
Channel 25 mm
width Reaction zone
8 mm

Thermocouple holes

Fig. 2. A diagram showing the dimensions of the catalytic plate reactor.

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.

and weaker, resulting in a decrease in viscosity [14]. This behavior of


both samples suggests that they can be used for coating; whereas a
shear thickening behavior can cause problems during a coating
process leading to coating streaks and poor adherence to the
substrate. On the other hand, hysteresis test and step test with Fig. 6. EDX analysis of three coats of catalyst calcined at 400 °C over a metal shim. A: Ni
(25%)/Al2O3 (75%); B: Ni (50%)/Al2O3 (50%).
three intervals were conducted to investigate the thixotropic behavior
of sol–gel, but both samples did show noteworthy time-dependent
behavior. The Herschel–Bulkley model best described the flow curves where τ is the shear stress in Pa, τ0 is the yield stress in Pa, γ̇ is the
of both samples; see Fig. 8. shear rate in 1/s, m is the consistency coefficient and n is the flow
behavior index. Herschel–Bulkley materials that behave as a rigid
solid under the effect of shear stress lower than a finite stress are
n
τ = τ0 + mγ̇ ð3Þ known as the yield stress. The rheological parameters obtained for
samples with different nickel contents are listed in Table 2. The yield
stress of 25% Ni sample is greater than that of 50% Ni samples. Since
A the magnitude of the yield stress τ0 depends on the strength of the
particle network, these values indicate that interparticle forces are
strong when nickel content is 25% compared with the sample of 50%
Ni content. In fact the yield stress decreases with increasing the nickel
content beyond 25%. The value of n for the nickel-containing samples
is less than one which confirms the shear thinning behavior of these
samples. The 25% Ni sample has a lower flow behavior index than
those of the 50% and 75% Ni, indicating its higher pseudoplasticidity.
This explains the higher surface area obtained for coating with this
sample. On the other hand, the higher n value of 50% Ni sample (0.51)
means that it is near-Newtonian behavior (n = 1) with more stable
structure. In addition, at high shear rate, the 50% Ni sample showed
constant viscosity (Fig. 7), which indicates that it is more stable than

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

0.3 Conversion 620


Avg. temperature

10 100 1000 0.2 600


0 2 4 6 8 10 12 14 16
Shear Rate (1/s) Continuous time on stream (h)

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

Activation Energy (kJ/mol)


indicative of completely hydrodynamically controlled material 120
structure [15].
100
3.4. Catalytic activity test
80
The catalyst preparation method outlined above produced Ni
(50%)/Al2O3(50%) catalyst that adhered well to stainless steel (type 60
316) and showed a high activity. Two coats of sol–gel with
intermediate drying gave a catalyst loading of 4.8 mg/cm2 after 40
calcination. This catalyst film gave above 80% methane conversion
20
when continuously used for more than 15 h at 40 psig (276 kPa)
pressure and temperature from 625 to 720 °C as shown in Fig. 9. The 4 5 6 7 8 9 10
methane flow rate was 0.58 mol/h with a 3:1 M steam: methane ratio. Catalyst Loading (mg/cm 2)
This study focuses mainly on catalyst preparation and characteriza-
tion. An important and significant feature of the prepared catalyst is
Fig. 10. Activation energy vs. catalyst loading over 50 wt.% Ni/Al2O3.
the reduction of mass transfer limitation and will be discussed in
Section 3.5. A thorough evaluation of the catalyst performance
including comparison with other catalysts or previous studies is still to 45 μm, based on the density of 50 wt.% Ni/Al2O3 catalyst estimated
under investigation and will be presented in an upcoming publication. at 2 g/cm3. These activation energy values represent the apparent
activation energy, assuming that the methane reaction is first order.
3.5. Diffusion limitation As a rule of thumb, chemical reaction will be rate limiting if the
apparent activation energy is greater than 40 kJ/mol; if it is in the
In catalytic plate reactors, small channels coated with a thin range of 12–15 kJ/mol or lower then the transport processes are
catalyst film offer short diffusion and conduction path lengths for assuming a greater degree of control over the reaction [16]. This
rapid mass, and heat transfer. This results in minimal intra-catalyst clearly indicates that in the range of catalyst loadings examined in this
diffusion limitations and thus high catalyst utilization (effectiveness study, the steam reforming reaction apparent activation energy values
factor ≈ 1). However, results showed that increasing the catalyst are too high for any diffusion limitation.
loading in the plate reactors results in enhancement of methane
conversion under the same reaction conditions. The catalyst thickness 4. Conclusions
is estimated to be up to 50 μm, assuming that the layer is uniformly
deposited and has a porosity of 35%. At such thickness, internal mass • It has been demonstrated that sol gel method facilitates catalyst
and heat transfer resistances are considered to be negligible. The preparation. The sol–gels can be prepared to have good rheological
activation energy of Nickel/Alumina catalyst decreases as catalyst properties for coating onto stainless steel substrate, which can form
loading increases as shown in Fig. 10. The apparent activation energy an adherent thin catalyst layer with good metal dispersion.
varied from 100 to 92 kJ/mol as the catalyst thickness varied from 22 • The results indicated that the highest surface area of calcined Ni/
Al2O3 catalyst was at 400 °C for all catalyst ratios and decreased with
the increment of nickel content.
Table 2
• Presence of nitrogen gas stream during drying and calcining on the
Herschel–Bulkley parameters for samples with different nickel contents (0–75% Ni).
catalyst surface area was beneficial for all catalyst ratios.
Ni% τo (Pa) m (Pa ⋅ sn) n R2 • Samples with 50% nickel contents had more stable structure due to
0 0.0 0.0067 1.0 0.998 the high flow behavior index (n) and Newtonian behavior at high
25 12.40 0.882 0.37 0.986 shear rate.
50 9.20 0.321 0.51 0.994 • The nickel/alumina sol–gel mixtures showed shear-thinning and
75 3.45 0.355 0.51 0.980
noteworthy time-dependent behavior.
M.A. Al-Nakoua et al. / Fuel Processing Technology 92 (2011) 1836–1841 1841

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