Alkaline Earth Metal Oxide Catalyst Support for Syngas Reforming
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Solution Overview
Problem
Current hydrocarbon gas reforming catalysts are prone to sintering and carbon formation (coking), leading to reduced efficiency and catalyst failure, especially when producing syngas with a CO/H2 ratio of 1:1, which requires separation techniques increasing costs and decreasing production efficiency.
Innovation Solution
Using alkaline earth metal/metal oxide compounds as a support material for catalytic materials, such as MgAl2O4, CaAl2O4, or SrAl2O4, to reduce sintering and coking issues, with the catalytic material attached through chemical or physical bonds, and operating at temperatures above 700°C to maintain catalyst durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for hydrocarbon gas reforming, then syngas production is achieved, but sintering and coking occur leading to reduced catalyst efficiency and durability
Solution Approach 1:
The patent uses composite support materials consisting of alkaline earth metals (Mg, Ca, Sr, Ba) combined with metal oxides (Al2O3, SiO2, ZrO2, TiO2, CeO2) to create a synergistic effect that simultaneously prevents sintering and coking while maintaining high syngas production efficiency
Solution Approach 2:
The alkaline earth metal/metal oxide compounds act as intermediary support materials between the catalytic material and the reaction environment, providing a stable platform that mediates against sintering and coking while facilitating the reforming reaction
2Productivity
If water is used as the oxidant in methane reforming, then syngas is produced with a CO/H2 ratio of 1:3, but separation techniques are required to achieve the desired 1:1 ratio, increasing costs and decreasing efficiency
Solution Approach 1:
The patent changes the chemical parameter of the oxidant from water to carbon dioxide (or a mixture of carbon dioxide and oxygen), which fundamentally alters the stoichiometry of the reforming reaction to produce syngas with a CO/H2 ratio of approximately 1:1, eliminating the need for complex separation processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The alkaline earth metal/metal oxide supported catalysts effectively reduce sintering and coking, maintaining catalyst efficiency and durability, allowing for efficient syngas production with a CO/H2 ratio of 1:1 without the need for costly separation techniques.
Implementation Method 1
One of the issues with current catalysts is that they are prone to sintering, which can reduce the active surface area of the catalytic material, thereby reducing the efficiency of the catalyst. Another issue is that of carbon formation or coking... Catalytic materials supported by these compounds have been shown to have reduced coking and sintering issues during the syngas production/reaction process.
Implementation Method 2
Another issue is that of carbon formation or coking, which can also occur on the catalytic material. The catalysts used in the above methane/carbon dioxide reforming reactions are especially prone to sintering and coking issues, both on the surface of the actual catalytic material and the surface of the support material... Catalytic materials supported by these compounds have been shown to have reduced coking and sintering issues during the syngas production/reaction process.
Implementation Method 3
Catalysts are used to drive the above reforming reactions... A 1:1 ratio can also be obtained by replacing water with carbon dioxide or a mixture of carbon dioxide and oxygen, such as by the following reactions: CH4+CO2→2CO+2H2; 2CH4+CO2+O2→3CO+3H2+H2O.
Implementation Method 4
The attachment can be through chemical bonds or physical bonds or both.
Implementation Method 5
The attachment can be through chemical bonds or physical bonds or both.
Data Source
AI summary
Disclosed is a hydrocarbon gas reforming supported catalyst, and methods for its use, that includes a catalytic material capable of catalyzing the production of a gaseous mixture comprising hydrogen and carbon monoxide from a hydrocarbon gas, and a support material comprising an alkaline earth metal/metal oxide compound having a structure of D-E, wherein D is a M1 or M1M2, M1 and M2 each individually being an alkaline earth metal selected from the group consisting of Mg, Ca, Ba, and Sr, E is a metal oxide selected from the group consisting of Al2O4, SiO2, ZrO2, TiO2, and CeO2, wherein the catalytic material is attached to the support material.