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Abstract:
The dry reforming of CH4 was investigated in a catalytic fixed-bed reactor to produce hydrogen at different
temperatures over supported bimetallic Ni-Co catalyst. The reactor model for the dry reforming of methane
used a set of kinetic models: The Zhang et al model for the dry reforming of methane (DRM); the Richardson-
Paripatyadar model for the reverse water gas shift (RWGS); and the Snoeck et al kinetics for the coke-deposition
and gasification reactions. The effect of temperatures on the performance of the reactor was studied. The
amount of each species consumed or/and produced were calculated and compared with the experimental
determined ones. It was showed that the set of kinetic model used in this work gave a good fit and accurately
predict the experimental observed profiles from the fixed bed reactor. It was found that reaction-4 and reaction-
5 could be neglected which could explain the fact that this catalyst coked rapidly comparatively with other
catalyst. The use of large amount of Ni-Co will lead to carbon deposition and so to the catalyst deactivation.
Keywords: dry reforming of methane, greenhouse gas, modelling, catalytic reactor, coke deposition
DOI: 10.1515/ijcre-2016-0170
1 Introduction
The CO2 methane reforming has been, for a long time, a subject of several studies. This process has important
environmental and economic implications, since it utilizes both methane and carbon dioxide, two greenhouse
gases that cause global warming, to produce useful chemical products (Al-Fatesh, Fakeeha, and Abasaeed 2011).
In recent years, the Ni-based catalysts have gained much attention despite their deactivation due to the
excessive deposition of carbon during the catalytic conversion process. For this purpose, many investigators
(Hu and Ruckenstein 2002; Bradford and Vannice 1999) concentrated their studies on the suppression of carbon
formation which is stopping the catalytic reforming of methane to be used commercially.
The supported group VIII metal catalysts have been used extensively in the methane dry reforming (DRM).
The noble metals (e. g. Ru, Rh, Pd, Pt, Ir) as well as non-noble metals (e. g. Ni, Co, Fe) were found to be catalyti-
cally active towards this reaction (Rostrup-Nielsen and Bak Hasen 1993). The noble metal is active and have been
found to be less prone to coke formation under reforming conditions. The drawback of noble metal catalysts is
their high cost and limited availability. In contrast, non-noble metals are less expensive and widely available.
However, dry reforming being strongly endothermic requires high temperatures (typically 800–900 °C) and this
leads to the rapid deactivation of the catalyst by carbon deposition and/or metal sintering for non-noble (Liu
2010).
At the industrial level, the catalyst properties and operating conditions must be carefully selected to mini-
mize undesirable transient modifications of the active catalytic phase, e. g., by deactivation and coking (Chen
et al. 2010). Several methods and different nickel-based catalysts have been proposed for reducing coke forma-
tion, however, a solution has still not been found (Corthals et al. 2011; Tomishige and Fujimoto 1998; Zhou et
al. 2011).
It has been reported that the replacement of 50 mol% of the NiO by CoO in NiO-MgO (Ni/Mg=1), improved
the performance of the catalyst in the methane to syngas conversion process; and drastically reduced the carbon
formation on the catalyst (Choudhary and Mamman 1998). The addition of Co leads to the strong adsorption
capacity of CO2 which, in turn, favours the elimination of carbon. There are reports that the catalyst activity and
stability can be improved through formation of a homogeneous alloy between Co and Ni (Takanabe et al. 2005).
Xiaohong et al. (2010), Zhang, Wang, and Dalai (2007), and Koh et al. (2007), reported that bimetallic catalysts
performed better than the corresponding monometallic catalysts. Zhang, Wang, and Dalai (2008) showed that
the change of the metal dispersion and metal particle size facilitated the improved activity and coke suppression
of Ni–Co bimetallic catalysts. In addition, in their previous work, Zhang, Wang, and Dalai (2007) showed that
reducing Ni and Co content from 6.1 and 9.3 to 3.6 and 4.9 mol% (metal base), respectively, rendered to eliminate
carbon deposition.
The major drawback of DRM is the high temperatures required to reach high conversion. This is due to the
highly endothermic nature of the reaction.
The present work deals with Ni-Co alumina supported catalyst (16.5 wt.% Ni; 16.5 wt.% Co). The objective
was to show the effect of promoting the Ni catalyst with Co on the catalytic activity and the resistance to coke for-
mation during the reaction. Previous results (Benguerba et al. 2015) showed that a Ni/Al2 O3 catalyst (33 wt.%
Ni content) yielded similar results. The experimental work was conducted to validate the one-dimensional
mathematical model for the catalytic fixed-bed reactor operating at steady-state conditions.
dXCO2 ρb ωL
= (r1 + r2 + r5 ) [7]
dz F0CO
2
dXCO ρ ωL
= b0 (2∗r1 + r2 + r4 + 2𝑟5 ) [8]
dz FCH
4
dXH2 ρb ωL
= (2∗r1 − r2 + 2∗r3 + 𝑟4 ) [9]
dz F0CH
4
dXH2 O ρb ωL
= (r2 − r4 ) [10]
dz F0CH
4
Table 1: Reaction rates equations: DRM; RWGS; coke formation and gasification.
Dry reforming of methane
2
u�1 PCH4 PCO2 (PCO PH2 )
Reaction-1 (Zhang, Wang, and Dalai 2009) r1 = (u�u�u�2 ,1 PCO2 +KCH4 ,1 PCH4 )
(1 − KP1 (PCH4 PCO2 )
)
k2 KCO2 ,2 KH2 ,2 PCO2 PH2 (PCO PH2 O )
Reaction-2 (Richardson and Paripatyadar 1990) r2 = 2 (1 − KP2 (PCO2 PH2 )
)
(1+KCO2 ,2 PCO2 +KH2 ,2 PH2 )
P2
H ⎞
k3 KCH4 ,3 ⎛
⎜PCH4 − K 2 ⎟
⎜ ⎟
p3
Reaction-3 (Snoeck, Froment, and Fowles 1997a) r3 = ⎝ ⎠
2
(1+KCH4 ,3 PCH4 + K 1 P1.5 )
H2 ,3 H2
k4 PH O P
KH O,4
( P 2 − KCO )
Reaction-4 (Snoeck, Froment, and Fowles 2002)
H2 P4
r4 = 2
PH O 2
(1+KCH4 ,4 PCH4 + K 1 2 + 1 P1.5 )
KH ,4 H2
H2 O,4 PH2 2
k5 PCO P
KCO,5 KCO ,5
( P 2 − KCO )
Reaction-5 (Snoeck, Froment, and Fowles 2002)
CO P5
r5 = 2
PCO 2
1 2)
(1+KCO,5 PCO + K
CO,5 KCO2 ,5 PCO
Table 2: Thermodynamic and rate constants. Constants are in [mol, kg, s, bar].
Parameter Value Parameter Value
k1 (Zhang, Wang, and 1.3510 −8
exp (− 3115.22
T
) KH2O,4 (Snoeck, Froment, 4.7310−6 exp (+ 97770
RT
)
Dalai 2009) and Fowles 2002)
k2 (Richardson and 0.35106 exp (− 81030
RT
) KCH4,4 (Snoeck, Froment, 0
3.49exp (− RT )
Paripatyadar 1990) and Fowles 2002)
k3 (Snoeck, Froment, and 6.95103 exp (− 58893
RT
) KH2,4 (Snoeck, Froment, and 1.8310+13 exp (− 216145
RT
)
Fowles 1997a) Fowles 2002)
k4 (Snoeck, Froment, and 5.55109 exp (− 166397
RT
) KCO,5 (Snoeck, Froment, 7.3410−6 exp (+ 100395
RT
)
Fowles 2002) and Fowles 2002)
k5 (Snoeck, Froment, and 1.341015 exp (− 243835
RT
) KCO2,5 (Snoeck, Froment, 2.8110+7 exp (− 104085
RT
)
Fowles 2002) and Fowles 2002)
KCO2,1 (Zhang, Wang, and 9.2510−8 exp (+ 4883.32
T
) Kp1 (Zhang, Wang, and 6.7810+14 exp (− 259660
RT
)
Dalai 2009) Dalai 2009)
KCH4,1 (Zhang, Wang, and 2.4610−7 exp (+ 4606.68
T
) Kp2 (Richardson and 56.4971exp (− 36580
RT
)
Dalai 2009) Paripatyadar 1990)
KCO2,2 (Richardson and 0.5771exp (+ 9262
RT
) Kp3 (Snoeck, Froment, and 2.9810+5 exp (− 84400
RT
)
Paripatyadar 1990) Fowles 1997a)
KH2,2 (Richardson and 1.494exp (+ 6025
RT
) Kp4 (Snoeck, Froment, and 1.382710+7 exp (− 125916
RT
)
Paripatyadar 1990) Fowles 2002)
KCH4,3 (Snoeck, Froment, 0.21exp (− 567
RT
) Kp5 (Snoeck, Froment, and 1.939310+9 exp (− 168527
RT
)
and Fowles 1997a) Fowles 2002)
KH2,3 (Snoeck, Froment, and 5.1810+7 exp (− 133210
RT
)
Fowles 1997a)
2.2 Kinetics
For the DRM and the RWGS reactions, the kinetics given by Zhang, Wang, and Dalai (2009)and by Richardson-
Paripatyadar (Richardson and Paripatyadar 1990) respectively were used. The kinetic models developed by
Snoeck, Froment, and Fowles (1997a, 1997b, 2002) were used for the carbon deposition and gasification reac-
tions (Table 1). For the Zhang et al kinetic model, we have added a term to the original model to account for the
reverse reaction (1).
Thermodynamic and rate constants for the rate equations for DRM, RWGS and for coke formation and
gasification are given in Table 2.
Figure 2: Comparison between the experimental and the simulated molar fluxes obtained at the exit of the reactor at op-
erating conditions (Table 3); open circle CH4 -experimental; dotted line CH4 -simulated; open square CO2 -experimental;
line CO2 -simulated; open triangle CO-experimental; dashed line CO-simulated; open diamond H2 -experimental; long
dash line H2 -simulated.
Figure 3 shows, the influence of the temperature, on the rates of CO2 reforming of methane over the
Ni-Co/Al2 O3 catalyst at atmospheric pressure. The competition between reaction-1 and reaction-3 to convert
CH4 to syngas is clearly presented, showing that the dominant reaction is reaction-1. Reaction-3 is lower, but
coke is significantly produced.
Figure 3: Effect of the wall temperature on the dry reforming reactions rates at operating conditions (Table 3); dotted line
reaction_1; medium dash line reaction_2; short dash line reaction_3; continuous line reaction_4; broken line reaction_5.
Unlike the case of Ni/Al2 O3 (Benguerba et al. 2015), the use of a bimetallic catalyst, Ni-Co/Al2 O3 makes
the reaction-4 very low or even negligible and reaction-5 very low. This is probably due to the high content of
nickel and cobalt in the catalyst giving greater metal sizes and consequently made the catalyst less coke resistant
(Zhang, Wang, and Dalai 2008). This finding was confirmed experimentally because this catalyst was found to
coke very quickly after a few hours of operation: The large quantities of coke produced by reaction-3 are not
gasified by the very low reaction-4 and reaction-5 leading to a coked catalyst. This result is in full agreement
with the results obtained experimentally by Zhang, Wang, and Dalai (2008): the higher is the Ni-Co content
(16.5 wt.% Ni; 16.5 wt.% Co), the higher is the carbon deposition extent. For temperatures 650 and 700 °C, the
reaction of gasification by CO2 is very significant at the entrance of the catalytic bed but it soon becomes very low
in the center and near the exit of the catalyst bed. Figure 3 shows that the peak of production of the reaction-3
(carbon deposition) starts at Z > 0.5 for low temperatures (T = 450 and 500 °C), but begins to move toward the
inlet of catalyst bed (Z = 0.48) for high temperatures. This peak of the reaction-3 is accompanied by a very small
gasification reaction-4 and reaction-5. It is concluded that the deactivation of the catalyst should be mainly in
the center of the catalyst and a little less at the exit of the catalyst bed.
Figure 4 shows the simulated temperature profiles at different wall temperatures (Tw ). The obtained results
indicated the global endothermicity of the chemical scheme. In the entrance of the catalyst bed, it is observed
a deep decrease of the temperature (endothermic global reaction) especially at high wall temperatures. As the
wall temperature increased, the endothermicity of the global reaction increased. This is due to the activation of
the reaction set in the endothermic way.
Figure 4: Evolution of the reactor temperature profiles at operating conditions (Table 3) with different wall temperatures;
broken line 450 °C; long dash line 500 °C; medium dash line 550 °C; short dash line 600 °C; dotted line 650 °C; continuous
line 700 °C.
The problem that must be pointed out is the heat transfer efficiency from the external wall to the catalyst
bed. The consumed heat in the endothermic process was not compensated in the catalyst zone by the heat
transmitted from the external wall. This raises several questions about the effectiveness of heat transfer in such
reactors. The heat transfer limitation for packed-bed reactors could alternatively be solved by coating a thin
layer of the catalyst on the inner walls of the reactor, thus avoiding the pressure drop associated with packed
bed reactors. The temperature could be easily controlled and the reactor will operate near isothermally.
4 Conclusion
Dry reforming of methane over a Ni-Co/Al2 O3 catalyst has been kinetically modelled. The reaction scheme
consisted of five reactions: the DRM, the RWGS, methane decomposition, and the two gasification reactions.
The kinetic rates used in this study was the Zhang et al model for the DRM; the Richardson-Paripatyadar model
for the RWGS reaction; and the Snoeck et al models for coke deposition and gasification reactions. It was found
that reaction-4 and reaction-5 could be neglected which could explain the fact that this catalyst coked rapidly
comparatively with other catalyst. The use of large amount of Ni-Co will lead to carbon deposition and so to
the catalyst deactivation.
The simulation of the wall-heated reactor system showed that the conversion, as well as the temperature
profiles, are dependent on the heated-wall temperature. It is noticed a weak heat transfer efficiency which is a
major drawback of such reactors.
Nomenclature
cp heat capacity (J kg−1 K−1 )
Dt inlet reactor diameter (m)
𝐹u�0 initial molar flow for species i (mol/s)
k reaction rate constant (see Table 2)
K adsorption constant (see Table 2)
Kp equilibrium constant for reaction i (see Table 2)
L reactor length (m)
P pressure (bar)
r specific rate of reaction (mol kg−1 s−1 )
R universal gas constant (J mol−1 K−1 )
T temperature (K)
u gas velocity (m s−1 )
Uw overall heat transfer coefficient (W/m2 K)
Xi conversion for (CH4 and CO2 ); Yield for (CO, H2 O, H2 )
z axial coordinate (m)
𝜌u� catalyst bed density (kg/m3 )
𝜌u� gas density (kg/m3 )
ω catalyst mass (kg)
𝜀 bed porosity (-)
ΔH heat of reaction (kJ mol−1 )
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