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Ind. Eng. Chem. Res.

2007, 46, 5265-5270 5265

KINETICS, CATALYSIS, AND REACTION ENGINEERING

Kinetic Analysis of Rate Data for Dry Reforming of Methane


Marı́a Martha Barroso Quiroga and Adolfo Eduardo Castro Luna*
Facultad de Ingenierı́a y Ciencias Económico-Sociales, INTEQUI-CONICET-UNSL, AV. 25 de Mayo 384,
5730 Villa Mercedes (S.L.), Argentina

The kinetics of the CO2 reforming of methane was investigated on a Ni-Rh-Al2O3 catalyst. Twenty-seven
mechanistic models were considered and fitted to the experimental data by numerically integrating the rate
equation of the dry reforming of methane reaction. A thermodynamic analysis showed that the reverse water
gas shift reaction operates in or very close to thermodynamic equilibrium. A strategy of model discrimination
and parameter estimation led to a model that considers CO2 molecular adsorption, CH4 dissociative adsorption,
and its surface chemical reaction as the rate-determining step. The parameter estimates in the resulting model
are statistically significant and thermodynamically consistent.

Introduction reaction 1 is highly dependent on feed composition and


conversion. For supported Pt, Ni, and Ru catalysts, Bradford
Carbon dioxide reforming of methane or dry reforming of
and Vannice12,15 have proposed that the CH4-CO2 reaction
methane (DRM) to synthesis gas has lately attracted renewed
proceeds via reversible dissociation of CH4 to form CHx and H
interest. An advantage of producing synthesis gas1 by this route,
species, followed by quasi-equilibrated steps, where CO2
instead of using steam reforming or partial oxidation, is the low
adsorbs, dissociates, and reacts with CHx and hydroxyl groups
H2/CO ratio obtained, which is of particular interest in the
to form CHxO species. In this proposal, CHxO dissociates to
synthesis of valuable oxygenated products, such as alcohols and
form adsorbed CO and H, which then desorb to form CO and
aldehydes. A large number of supported catalysts with promis-
H2. Other authors16 have reported the absence of CHx species
sory catalytic activity have been proposed for methane reform-
on the catalyst surfaces, suggesting that the interaction of CHx
ing.
with surface oxygen is fast, to form CHxO via
The deposition of carbonaceous species on the catalyst active
sites represents an important limitation to the reaction, producing
CHx + O f CHxO (7)
deactivation and pressure rise due to blocking of the catalyst
pores and voids, which causes pressure increases in the reformer
furnace tubes.2 Another recently proposed mechanism14 indicates that CH4
Because of their low cost, Ni based catalysts are often decomposes to chemisorbed C in a series of elementary
preferred.3 Also, it has been reported in the literature that group H-abstraction steps, which become increasingly fast as H atoms
VIII metals are catalytically active and selective for this are withdrawn from CH4, the first H-abstraction being the
reaction.4,5 Particularly, Rh-based catalysts exhibited very low kinetically relevant step. CO2 is dissociatively adsorbed on the
carbon formation. Several studies involving the development catalyst surface as CO and O.
of bimetallic Ni-Rh catalysts suggested the formation of Ni- Previous work on the kinetics of the DRM reaction has
Rh alloys.6-9 reported an apparent activation energy range between 29 and
While the thermodynamics of the reaction is well under- 306 kJ/mol.11
stood,10 knowledge about the reaction mechanism and kinetics The aim of this work is to find a rate equation that describes
is still highly controversial.12-14 Methane reforming belongs to the system behavior in operating conditions, to use it later in
a rather complex reaction network: the design and/or simulation of an industrial reactor.
We undertook this work because in spite of the importance
CH4 + CO2 T 2CO + 2H2 (1)
of and interest in the reaction the mechanism of the reaction is
CO2 + H2 T CO + H2O (2) not yet understood, and there are no expressions that reasonably
describe the kinetics of the process.
CO2 + 4H2 T CH4 + 2H2O (3)
CH4 + H2O T CO + 3H2 (4) Experimental Section
CH4 T C + 2H2 (5) Equipment and Materials. The experiments were carried
out in a conventional continuous-flow reactor.
2CO T C + CO2 (6)
Feed Section. Gaseous CH4, H2, N2, and CO2 are fed to the
As can be deduced readily from the equations, the importance system by automatic mass flow meters.
of the reactions 2-6 for the overall product composition of Reactor. The reactor is a quartz tube, 850 mm long, with an
inner diameter of 16 mm. The catalyst sample (diluted with
* To whom correspondence should be addressed. E-mail: cstrln@ inert R-Al2O3) is loaded into the reactor, with a 1:10 ratio to
fices.unsl.edu.ar. avoid axial and radial temperature profiles.
10.1021/ie061645w CCC: $37.00 © 2007 American Chemical Society
Published on Web 07/03/2007
5266 Ind. Eng. Chem. Res., Vol. 46, No. 16, 2007

[ ]
-∆H ln(1 + δpCH4/Pt)
Analysis Section. Effluent gases are analyzed in a Shimadzu
GC-3A gas chromatograph, which uses Ar as the carrier and a (∆T)max ≈ 0.7 (9)
Mmcp δ
Carbosphere 80/100 column. The results are then evaluated
automatically by a DeskJet Spectra-Physics 4600 integrator. The The conditions are as follows: T, 898 K; Pt, 1.1 atm; W, 0.1 g;
gas chromatograph was capable of separating the four reaction XCH4, 0.2935; γ, 1; pCH4, 0.1675 atm; Ft, 4 × 10-4 kmol/h; rCH4,
gases, as far as water was condensed before the analysis. 0.4193 kmol/(kgcat h); pCH4, 1.4351 atm; Sc, 0.0473; Mm, 19.58
Catalyst Preparation. Our group has been studying the kg/kmol; am, 33.47 m2/kgcat; G, 77.91 kg/(m2 h); Re, 0.121; JD,
behavior of catalysts obtained by Ni impregnation or inclusion 4.879; ∆H, 259.53 kJ/mol; and cp, 6.107 kJ/(kg K). The results
in γ-alumina, which are obtained by different preparation are as follows: ∆PCH4 ) 1.21 × 10-4 atm and (∆T)max ≈ 0.128
procedures that include new technologies such as sol-gel K.
methods. In this case, a nickel-rhodium-alumina catalyst was Internal Mass-Transfer Effect. For spherical particles and
prepared by thermal decomposition and subsequent hydrother- first-order reactions with respect to the CH4 component, the
mal treatment, according to the following procedure: 162.37 Weisz-Prater modulus can be written as18
mmol of aluminum sec-butoxide was added to 70.8 g of a
solution of Ni 1-metoxi 2-propoxide in 1-metoxi 2-propanol rCH4Fsrp2RT
(0.0697 mmol of Ni/g of solution or 4.936 mmol of total Ni). D) e1 (10)
The noble metal precursor, Rh(NO3)3·2H2O (Johnson & Mat- pCH4De
they; 0.4926 mmol of total Rh), was also added to the alcoholic
The conditions are as follows: Fs, 956 kg/m3; rp, 9.4 × 10-5
solution made from aluminum and nickel alcoxides. This
m; and De, 0.015 m2/h. The results is D ) 0.105.
solution was exposed to ambient humidity and was left until it
was completely dry (T ) 308 K). Afterward, it was dried at
423 K for 12 h. The sample, diluted in water, was placed in a Experimental Results
reactor under pressure at 293 K for 13 h. Finally, it was calcined The operation variables were studied at atmospheric pressure
at 1123 K for 100 h. in the following ranges: reaction temperature, 778-898 K;
A typical test consists of the in situ reduction of the catalyst space-time, W/FCH40 (catalyst weight to CH4 molar feed rate
under hydrogen flow at 1123 K for 14 h. Then, the H2 flow is ratio at the reactor inlet), 0.2-0.7 g h mol-1; and feed ratio
replaced by an equimolar mixture of CH4-CO2, and the CO2/CH4, (F), 1.0 molCO2/molCH4. The catalyst reached a
temperature is set to 1073 K until stationary conditions are constant activity level after 4-6 h on-stream, without showing
reached (4-6 h, approximately). The reaction temperature is signs of deactivation after 1 week of continuous operation.
lowered, and the composition of the reactor effluent is periodi- Exploratory tests varying the feed ratio of CO2/CH4 produced
cally measured until the minimum temperature is achieved. By deactivation, obtaining reproducible results only at stoichio-
changing the reactant flow rate, the space time, W/FCH40, is metric composition. Mark et al.,19 Bodrov et al.,20 and Erdöhelyi
changed from 0.2 to 0.7 g h mol-1. CH4 and CO2 conversions et al.21 obtained also reproducible results only at stoichiometric
are calculated using methane as the reference component, to feed ratios or with excess of CO2. Because of the reaction
which all the conversions are related. network described above and its dependence on feed composi-
The catalyst contains 14% of Ni and 1.4% of Rh. Its BET tion, the kinetics of the reforming reaction (eq 1) reported here
surface area is 173 m2/g, the pore volume is 0.57 cm3/g, and its have been studied only at stoichiometric feed composition under
mean pore radius is 119 Å. Catalyst loadings were grounded to integral conditions.
a particle size of 0.16-0.25 mm and loaded into the reactor Kinetic Analysis. The reaction equilibrium for the production
mixed with inert R-alumina of the same size. The reactor was of synthesis gas from CH4 reforming with CO2 (eq 1) is strongly
warmed up with H2 flow until 1123 K was reached, during a influenced by the simultaneous occurrence of the reverse water
period between 12 and 15 h. The study begins with a reference gas shift (RWGS) reaction (eq 2). Some authors have shown
test to check the catalyst activity (T ) 1053 K, P ) 1.0 atm, that the reverse water gas shift reaction operates very close to
feed ratio CO2/CH4 (F) ) 1, W/FCH40 ) 0.5 gcat h mol-1). thermodynamic equilibrium during CH4-CO2 reforming,11,15,22
Possible deactivation is checked by a periodic repetition of the while others have assumed that this reaction is at equilibrium
reference test. in the kinetic treatment to facilitate the analysis. Bradford and
The temperature profile along the catalyst bed was experi- Vannice11 have reported that the RWGS reaction is very close
mentally determined as isothermal, and the pressure drop was to thermodynamic equilibrium over a wide temperature range.
negligible. Our experimental results show CO2 conversions higher than
To investigate the absence of external and internal diffusional the corresponding CH4 conversions as a consequence of the
influences, a number of experimental tests were carried out, RWGS equilibrium.
concluding that their influence is negligible. Furthermore, The measured H2/CO ratios were always less than unity (see
calculations also proved that external mass and heat transfer Table 1) and showed good agreement with those calculated by
resistances were nonsignificant. Intraparticle diffusional limita- the stoichiometric demand given by eq 11, which means that
tions were ruled out using the Weisz-Prater criterion. The the reaction of dry reforming is influenced by the simultaneous
equations and results are shown in the following. occurrence of the RWGS reaction.12
External Mass and Heat Transfer Effects. The partial
pressure and temperature gradients between the flowing fluid H2/CO ) (3 - rCO2/rCH4)/(1 + rCO2/rCH4) (11)
and the exterior surface of the catalyst were evaluated through
the following equations and conditions from Froment and where rCH4 and rCO2 are the experimental rates of CH4 and CO2
Bischoff.17 conversions, respectively.
The converted CO/CO2 ratio ranges from 2 (i.e., the stoi-
rCH4MmPtSc2/3 chiometric value of DRM reaction) to 1 (i.e., the stoichiometric
∆PCH4 ) (8) value of RWGS reaction). In the absence of carbon deposition,
amGJD a CO/CO2 ratio ) 2 is possible only if the RWGS reaction does
Ind. Eng. Chem. Res., Vol. 46, No. 16, 2007 5267

Table 1. Catalytic Activity of the Catalyst


CH4 conversion CO2 conversion H2/CO H2/CO
T (K) (%) (%) (eq 11) (measured) CO/CO2 rCH4 (mol g-1 h-1) rCO2 (mol g-1 h-1)
848 12.8 21.6 0.49 0.49 1.59 0.64 1.72
826 8.2 15.4 0.39 0.41 1.53 0.41 1.18
798 6.0 10.6 0.44 0.38 1.57 0.20 0.55

not occur. In Table 1 our results show CO/CO2 ratios between carbon with CO2L and with OL. The selected models are by
1 and 2 suggesting the influence of the RWGS reaction. no means a complete survey of all possible kinetic equations.
Thermodynamic Analysis. The RWGS pressure ratio was Twenty-seven rate equations were formulated according to
determined to ascertain the extent of the RWGS equilibrium. the Langmuir-Hinshelwood-Hougen-Watson formalism for
Figure 1 shows this ratio as a function of temperature as well the DRM reaction.
as the corresponding thermodynamic equilibrium constant. Model Discrimination and Parameter Estimation. The
Despite the fact that the uncertainty in the calculation of the kinetic analysis of experimental results was carried out on the
water composition, as it was estimated from an overall material basis of the integral method. Estimated CH4 conversions were
balance, produces large confidence limits in the estimated obtained through integration of the continuity equation for the
RWGS pressure ratio, it can be concluded that the experimental reference component in a plug flow tubular reactor.
data are at or very close to equilibrium, over the entire So, for CH4
temperature range investigated. The same concept applied to
the DRM reaction showed that the DRM is significantly shifted dXCH4
toward the reaction products. ) rref (12)
Reaction Schemes. Elementary steps were considered, where d(W/FCH40)
CH4, CO2, CO, and H2 were associatively or dissociatively
adsorbed on the catalyst surface. Only one type of site was where rref ) f(Pj,θ) is the reaction rate of the DRM reaction; Pj
assumed where reactants compete for adsorption.6,9 represents the partial pressure vector, and θ is the parameter
Certain considerations were made for the proposed reaction vector.
elementary steps, to limit the number and steps of the reaction Parameter estimation was obtained by minimizing the objec-
mechanisms down to a reasonable value. These considerations tive function
are based on elementary steps that were considered to be
possible in the literature.11,14,23-26 n
1. Carbon dioxide is adsorbed on the catalyst surface as CO2L Φ) ∑ (xCH4,exp - xCH4,calc)2 (13)
or liberates CO, leaving an adsorbed oxygen atom. I)1
2. Methane is adsorbed on the catalyst surface. Adsorbed CH4
reacts with the adsorbed oxygen or dissociates to form chemi- where n represents the number of tests carried out, xCH4,exp are
sorbed radicals, such as CH3L, CH2L, CHL, and CL, liberating the experimental methane conversion values, and xCH4,calc are
hydrogen or forming HL. the methane conversion values estimated according to the model
3. The concentration of the carbon-containing radicals, CH3L, in each test and obtained through integration of the continuity
CH2L, CHL, and CL, is less than the total concentration of the equation for the reference component. A fourth-order Runge-
active sites. Kutta routine was applied.
4. Adsorbed oxygen reacts with the carbon-containing radicals Minimized values were estimated through a single response
to form COL or to liberate CO. routine applying Marquardt’s algorithm.27
5. Adsorbed hydrogen, HL, reacts with the other ones at The parameter estimation was implemented with all the data
adjacent sites to liberate H2. at all temperatures. To speed up the convergence of the
The combination of these elementary steps led to the proposal minimization procedure, the rate and adsorption parameters were
of 27 different mechanisms, considering the surface chemical reparameterized to increase the parameter search rate and
reaction as the rate-determining step. The proposed kinetic minimize the statistical correlation between the pre-exponential
scheme, Figure 2, shows two different forms of the parallel factor and the activation energy (or, for adsorption constants,
formation of CO: from the reaction of radicals that contain the heat of adsorption); the temperature-dependent constants
were reparametrized by

Figure 1. Extent of the RWGS equilibrium as a function of temperature.


9: calculated RWGS pressure ratio. Solid line: RWGS thermodynamic
equilibrium constant. Figure 2. Kinetic scheme.
5268 Ind. Eng. Chem. Res., Vol. 46, No. 16, 2007

( (
k ) kTm exp -
Ea 1
-
R T Tm
1
)) (14)
Table 2. Reaction Scheme and Corresponding Steps in Figure 2
CO2 + L
CH4 + L
) CO2L
) CH4L
step 1
step 3

[ ( )]
CH4L ) CH3L + H2 step 4
∆Hi 1 1 CH3L + CO2L ) 2 CO + 2 H2 + 2 L step 18 r.d.s.
Ki ) Ki,Tm exp - - i ) CH4,CO2, etc.
R T Tm
(15) Table 3. Optimized Parameters for the Selected Modela
parameter activation energy or adsorption
where Tm is the average temperature for all the tests. parameter estimate enthalpy
The preexponential factors A(k) and A(Ki) can be calculated k1,Tm 14.13 A(k1) 3.59 × 1021 mol bar-2 g-1 h-1
from the kTm and Ea and Ki,Tm and ∆Hi values by the Arrhenius (t) (2.2)
E1 46.98 E1 3.32 × 105 J/mol
equation and van’t Hoff equation, respectively. (t) (12.7)
2.89 × 10-8 mol bar-2 g-1 h-1

( )
KCH4,Tm 0.16 A(KCH4)
Ea (t) (3.7)
A(k) ) kT exp (16) ∆HCH4 -15.52 ∆HCH4 -1.09 × 105 J/mol
RT (t) (-3.8)

( )
KCO2,Tm 1.79 A(KCO2) 3.52 × 10-8 mol bar-2 g-1 h-1
∆Hi (t) (2.3)
A(Ki) ) Ki,T exp (17) ∆HCO2 -177.44 ∆HCO2 -1.25 × 105 J/mol
RT (t) (-6.4)

The adequacy of the fit of each set of rate equations was


a Tm ) 850 K.
tested by means of the F value, and the significance of the Table 4. Activation Energy and Reaction Enthalpy Changes
parameters was tested by means of the t value and 95%
activation energy (kJ/mol)
confidence interval of the parameter estimates. The F value is
calculated by dividing the mean squares due to regression (the Ea ) 332.04
sum of the squares of the predicted responses divided by the reaction enthalpy change (kJ/mol)
number of parameters) by the mean residual squares (the sum
298 K 850 K
of residual squares divided by the degree of freedom of residuals,
which is the number of experiments minus the number of ∆H0 ) 247.30 ∆H0 ) 259.89
parameters). The t value of a parameter estimate is the ratio of
the parameter estimate minus zero and the standard deviation In reference to the model fitting, the value F obtained from
of that parameter. If a parameter is found to have a very small 9954.78 is 3 orders of magnitude larger than the tabulated 99%
t or a large confidence interval including zero, it is considered value, which is 3.186. The model exhibits parameters that are
to have no significant contribution to the rate equation. statistically and physicochemically consistent. The adsorption
Consequently, it may be deleted from the latter. The adequacy constants must satisfy certain thermodynamic criteria proposed
of the models was tested by analyzing their residuals. Discrimi- by Boudart et al.28
nation between rival models was based on this statistical testing Thermodynamic Consistency of the Parameter Estimates.
and on their compatibility with the physicochemical constraints. Thermodynamics imposes the relation E1 - E-1 ) ∆H. Because
the activation energies for the forward and reverse reactions
are positive
Results and Discussion
After a reasonable number of trials, seven of the proposed E > ∆H (18)
models were considered as nonconvergent. Fourteen models
For the selected model, the activation energy satisfies this
were ruled out because their parameter estimates were statisti-
concept, as shown in Table 4. It is also in the activation energy
cally meaningless.
range reported in the literature for the DRM.11 Some authors,
In spite of the fact that three models had good statistical
such as Mark et al.19 and Bradford and Vannice,15 have obtained
fitting, they were discarded for presenting positive adsorption
activation energies lower than 247.3 kJ/mol, the minimum value
enthalpies. Finally, from the retained set of equations, three
of the enthalpy changes of the DRM reaction, which is in
models were found to fit the experimental data well, and the
contradiction with eq 18.
significant parameter estimates satisfied the Arrhenius and the
The adsorption constants, KCH4 and KCO2, have to satisfy a
van’t Hoff equations. Physicochemical criteria allowed arriving
number of thermodynamic criteria according to Boudart et al.28
at the best model that fits the experimental data and provides a
(1) ∆S0j,a < 0. The preexponential factors of the adsorption
mechanistic description of the reaction. Results are shown in
constants satisfy the following rule, A(KCH4) and A(KCO2):
Table 3.
The selected model has the following characteristics: the first
step of the reaction (steps 3 and 4 in Figure 2) implies adsorption ∆S0CH4,a and ∆S0CO2,a < 0 (19)
and decomposition of CH4 and nondissociative adsorption of
J
CO2 (step 1 in Figure 2) on the active sites of the catalyst or ∆S0CH4,a ) R ln[A(KCH4)] ) -144.31 (20)
probably on the support, and a subsequent surface reaction of mol‚K
both adsorbed species that constitutes the rate-determining step
J
(r.d.s, step 18 in Figure 2). This model shows an activation ∆S0CO2,a ) R ln[A(KCO2)] ) -142.66 (21)
energy with a positive sign and negative adsorption enthalpies mol‚K
(see Table 3).
The reaction scheme leading to the retained set of rate (2) ∆S0j,a in absolute value must be lower than Sj,g
0
.
equations and generated out of the detailed scheme of Figure 2
is shown in Table 2. |∆Sj,a
0
| < Sj,g
0
(22)
Ind. Eng. Chem. Res., Vol. 46, No. 16, 2007 5269

Table 5. Boudart’s Third Rule Applied to the Selected Model


0
∆Sj,a -12.2 + 0.0014∆H0CH4,a
component (J mol-1 K-1) (J mol-1 K-1)
CH4 -144.31 -203.77
CO2 -142.66 -225.75

The ∆S0j,a values obtained from ref 29 at T ) 298.15 K for


CH4 and CO2 are 186.27 kJ kmol-1 K-1 and 213.68 kJ kmol-1
K-1, respectively.
Thus,

|∆S0CH4,a| < S0CH4,g (23)

144.31 < 186.27

|∆S0CO2,a| < S0CO2,g (24)

142.66 < 213.68


Figure 3. Methane conversion, XCH4, as a function of space time, W/FCH40.
(3) The third criterion, -∆S0j,a < 12.2 - 0.0014∆H0j,a, is Dots represent experimental values of XCH4 vs W/FCH40; full lines are the
estimated XCH4 of the selected model vs W/FCH40, at different temperatures.
shown in Table 5.
(4) Usually, the absolute value of the entropy change is higher
than 42 kJ/(mol K). Because ∆S0CH4,a is 144.31 kJ mol-1 K-1
and ∆S0CO2,a is 142.66 kJ mol-1 K-1, this rule is also satisfied.
The final model exhibits enough thermodynamically consis-
tent parameters to allow a solid model justification.
The rate equation and its parameter values, with a 95%
confidence value, are

k1KCH4KCO2(pCH4pCO4/pH20.5 - pH21.5pCO2/Kref)
rref )
(1 + pCH4/pH20.5KCH4 + pCO2KCO2)2
(25)
where

k1 ) 3.59 × 1021 exp (332.04RT( 52.40) (26)

-109.68 ( 57.53
KCH4 ) 2.89 × 10-8 exp( ) (27)
RT Figure 4. Carbon dioxide conversion, XCO2, as a function of space time,
W/FCH40. Dots represent experimental values of XCO2 vs W/FCH40; full lines
-125.39 ( 39.11 are the estimated XCO2 of the selected model vs W/FCH40, at different
KCO2 ) 3.53 × 10-8 exp( ) (28) temperatures.
RT
The agreement between the model predictions and the formulated according to the Langmuir-Hinshelwood-Hougen-
experimentally measured conversions is shown in Figures 3 and Watson formalism.
4. When a strategy of model discrimination and parameter
estimation was applied, a model, which considers CH4 dissocia-
Conclusions tive adsorption, CO2 molecular adsorption, and their surface
chemical reaction, as the rate-determining step, was selected.
The kinetics of the CO2 reforming of methane was investi- The CO2 conversion values were calculated directly from CH4
gated at undiluted stoichiometric feed composition on a Ni- conversion values of the selected model.
Rh-Al2O3 catalyst, free of external and internal diffusional The selected model describes the system behavior under
limitations, in the temperature range 778-898 K, at atmospheric operating conditions, and its parameter values are statistically,
pressure. physicochemically, and thermodynamically consistent. The
No evidence of coke formation or deactivation was found obtained rate expression could be used in the design or
during the kinetic study. simulation of an industrial reactor.
On the basis of the kinetic and thermodynamic treatment of
the experimental data it was concluded that the RWGS reaction
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