Carbon Dioxide Reforming Catalyst with Alkaline Earth Carbonate
Solution Overview
Problem
Existing carbon dioxide reforming catalysts face challenges with carbon deposition, leading to instability and inefficiency in generating hydrogen and carbon monoxide from hydrocarbon feedstocks, particularly when using nickel-supported or ruthenium-supported catalysts, which are prone to deactivation by carbon deposition and unsaturated hydrocarbons.
Innovation Solution
A carbon dioxide reforming catalyst comprising a mixture of an alkaline earth metal carbonate (Ca, Sr, or Ba) and a catalytic metal (Ni, Rh, Ru, Ir, Pd, Pt, Re, Co, Fe, or Mo) supported on ATiO3, which suppresses carbon deposition and promotes efficient conversion of hydrocarbon feedstocks to hydrogen and carbon monoxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a nickel-supported catalyst is used for carbon dioxide reforming, then the catalytic activity is high, but carbon deposition occurs on the catalyst surface leading to deactivation
Solution Approach 1:
The patent introduces a carbonate layer as an intermediary substance between the nickel catalyst and the reaction environment. This carbonate layer acts as a protective mediator that suppresses carbon deposition on the nickel surface while maintaining catalytic activity, thereby resolving the contradiction between high productivity and stability
Solution Approach 2:
The patent creates a composite catalyst structure consisting of nickel particles supported on alumina with a carbonate layer. This composite material combines the high catalytic activity of nickel with the carbon-suppressing properties of the carbonate coating, achieving both high productivity and stability
2Object-affected harmful factors
If a ruthenium-supported catalyst is used to suppress carbon deposition, then carbon deposition is reduced, but the catalyst is poisoned by unsaturated hydrocarbons causing activity decrease
Solution Approach 1:
The patent uses a carbonate layer that can be easily formed and removed, serving as a temporary protective barrier during the reaction process. This disposable-like carbonate layer prevents carbon deposition without permanently modifying the catalyst structure, allowing the catalyst to maintain activity while resisting poisoning by unsaturated hydrocarbons
3Object-affected harmful factors
If the carbonate support is used in the catalyst, then carbon deposition is suppressed, but the carbonate may sinter at high temperatures reducing effectiveness
Solution Approach 1:
The patent modifies the physical and chemical parameters of the carbonate layer, including its thickness, composition, and structural configuration. By optimizing these parameters, the carbonate layer maintains its carbon-deposition-suppressing properties while resisting sintering at high temperatures, thus preserving both functionality and stability
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 catalyst effectively suppresses carbon deposition, maintains high activity, and efficiently generates hydrogen and carbon monoxide by promoting the decomposition and conversion of hydrocarbon feedstocks, even at high temperatures, while preventing sintering of the carbonate support.
Implementation Method 1
a catalytic metal promoting a decomposition reaction of a hydrocarbon feedstock gas
Implementation Method 2
a carbonate of at least one alkaline earth metal selected from the group consisting of Ca, Sr, and Ba... carbon deposition is suppressed
Data Source
Figure 1~2
AI summary
A carbon dioxide reforming catalyst and a manufacturing method thereof are provided, the catalyst enabling a hydrocarbon feedstock gas to react with carbon dioxide while carbon deposition is suppressed and being capable of efficiently generating hydrogen and carbon monoxide. A mixture containing a carbonate of at least one alkaline earth metal selected from the group consisting of Ca, Sr, and Ba and a catalytic metal promoting a decomposition reaction of a hydrocarbon feedstock gas is contained as a primary component. As the catalytic metal, a least one element selected from the group consisting of Ni, Rh, Ru, Ir, Pd, Pt, Re, Co, Fe, and Mo is used. In addition, ATiO3 (A is at least one alkaline earth metal selected from the group consisting of Ca, Sr, and Ba) is further contained. Manufacturing is performed through a step in which carbon dioxide is absorbed in an alkaline earth/Ti composite oxide having a carbon dioxide absorption ability.