Process and Nickel Based Nano-structured Catalysts for Methane Dry Reforming

Description:

Overview of Technology

The invention includes catalyst compositions, methods of catalyst fabrication, and methods of catalyst inclusion techniques to increase reactivity and maintain catalyst stability during syngas production. Other embodiments of this invention include compositions for the catalytic conversion of methane or natural gas into syngas.

Background 

Nickel-based catalysts are commercially used for methane reforming techniques due to the affordability over other noble metals. In addition, a carbon-resistant and sulfur-tolerant nickel-based catalyst has been sought after to face the shortcomings that other catalysts experience during dry reformation of natural gas to synthesis gas (syngas). The invention includes catalyst compositions, methods of catalyst fabrication, and methods of catalyst inclusion techniques to increase reactivity and maintain catalyst stability during syngas production. Other embodiments of this invention include compositions for the catalytic conversion of methane or natural gas into syngas. Regeneration and recycling of the catalysts is also detailed.

Description of Technology 

Nano-structured nickel based catalyst for dry reforming natural gas and CO2 into syngas, highly resistant to sulfur and carbon fouling. The new nanostructured nickel-based catalysts demonstrate remarkably high activity and stability for dry reforming methane, natural gas or biogas to synthesis gas. Rates of CO2 and methane conversion can be improved to over 95% with the activity of the catalyst staying constant after 500 hours run time with commercial pipeline natural gas. No carbon deposition is observe over the catalyst, and the catalyst exhibits sulfur tolerance when running with raw natural gas. The catalyst may be easily regenerated and recycled, greatly reducing life cycle costs compared to other commercially available catalysts. 

Benefits

The new catalysts are more efficient than existing methane reforming catalysts, have longer run time than existing catalysts, and more resistant to fouling than existing catalysts. 

Applications

Dry reforming of methane, natural gas and biogas.