Mesoporous Catalyst for Combined Reforming

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Solution Overview

Problem

Current methods for producing hydrogen, such as steam reforming and dry reforming, face challenges like high carbon dioxide emissions and catalyst deactivation due to carbon deposition, limiting the efficiency and applicability of synthesis gas production for processes requiring H2/CO ratios greater than 1.

Innovation Solution

A method involving a catalyst with a mesoporous support, metal nanoparticles, and a metal oxide coating layer is used for combined reforming, which allows for the simultaneous conversion of carbon dioxide and methane into synthesis gas without particle aggregation or carbon deposition, suitable for subsequent processes like the Fischer-Tropsch reaction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If steam reforming is used to produce hydrogen, then hydrogen production efficiency is improved, but carbon dioxide emissions increase significantly

Engineering Contradiction:

Improvehydrogen production efficiencyVSAvoidcarbon dioxide emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent combines steam reforming and dry reforming into a single integrated reaction system, allowing both CH4+H2O→3H2+CO and CH4+CO2→2H2+2CO reactions to occur simultaneously over the same catalyst bed, thereby achieving high hydrogen production while consuming carbon dioxide

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent converts carbon dioxide, which is normally a harmful emission product, into a useful reactant for dry reforming reaction, transforming it from a waste product into a source of additional hydrogen production and carbon management

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-generated harmful factors

If dry reforming is used to reduce carbon dioxide emissions, then carbon dioxide consumption is improved, but catalyst deactivation occurs due to carbon deposition

Engineering Contradiction:

Improvecarbon dioxide consumptionVSAvoidcatalyst stability

Core Design Contradiction:

Object-generated harmful factorsVSReliability

Solution Approach 1:

The patent modifies reaction parameters by introducing steam into the dry reforming system, changing the reaction environment to suppress carbon deposition through coke gasification reactions (C(s)+H2O→H2+CO) while maintaining carbon dioxide consumption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a composite catalyst system with Ni nanoparticles supported on mesoporous silica, combining the high activity of nickel for reforming reactions with the carbon-resistant properties of silica, creating a catalyst that is both active and stable

Inventive Principle:

Principle #40Composite materials

3Productivity

If combined reforming is used to produce synthesis gas, then hydrogen production is improved, but carbon deposition deactivates the catalyst

Engineering Contradiction:

Improvehydrogen productionVSAvoidcatalyst activity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent employs mesoporous silica support with controlled pore structures to disperse nickel particles uniformly and prevent their aggregation, while the porous structure allows efficient mass transfer and access to active sites, maintaining high catalytic activity

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent introduces steam as an intermediary substance that mediates between the reforming reactions and carbon deposition, facilitating coke gasification and preventing carbon accumulation on the catalyst surface

Inventive Principle:

Principle #24Intermediary (Mediator)

4Productivity

If high temperature is used for methane conversion, then reaction efficiency is improved, but catalyst sintering and deactivation occur

Engineering Contradiction:

Improvemethane conversion efficiencyVSAvoidcatalyst structure stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent creates local protective environments around nickel particles by coating them with silica layers, providing thermal protection and preventing sintering at high temperatures while maintaining the overall high temperature conditions necessary for efficient methane conversion

Inventive Principle:

Principle #3Local quality

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

This approach enhances the stability and durability of the catalyst, maintaining high conversion rates and preventing carbon precipitation, thus enabling efficient production of synthesis gas for applications requiring H2/CO ratios greater than 1.

Implementation Method 1

heat-treating in the presence of a catalyst, wherein the catalyst comprises: a mesoporous support, metal nanoparticles supported on the support, and a metal oxide coating layer coated on a surface of the support

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

a metal oxide coating layer coated on a surface of the support

Methodology Applied

Scientific EffectPhysical barrier protection:

Data Source

PatentUS11845666B2Method for preparing synthesis gas

Publication Date: 2023.12.19 HYUNDAI MOTOR CO LTD

AI summary

Disclosed is a method for preparing a synthesis gas. The method may include performing a combined reforming reaction by injecting a reaction gas including water (H2O) and heat-treating it in the presence of the catalyst. The catalyst may include a mesoporous support including regularly distributed mesopores, metal nanoparticles supported on the support, and a metal oxide coating layer coated on a surface of the support.