Methane cracking using Ni supported on porous and non-porous alumina catalysts

Porous and non-porous alumina catalysts were used as nickel supports to catalyze methane cracking. Different operating parameters were studied in a thermal gravimetric analyzer, including methane and hydrogen partial pressures, temperature and flow rate. During CH4 cracking, carbon builds up on the catalyst surface and therefore the catalyst requires periodic regeneration. Cycling tests were performed, using air during the regeneration phase to burn off the carbon. The results showed that the non-porous catalyst performed better than the porous catalyst in terms of cracking during the first cycle. Full regeneration of the catalysts by oxidizing the deposited carbon was achieved at 550 °C, while oxidation was very slow at 500 °C. After full regeneration, the performance of the porous catalyst became considerably better than the non-porous. The porous catalyst kept its activity for 24 cracking/regeneration cycles, while the non-porous catalyst lost half of its activity by the second cracking cycle and almost all of its activity after six cycles. NiAl2O4 formation and Ni sintering caused the non-porous catalyst activity loss. TPO results showed that two carbon types were deposited on the catalysts, namely Cβ and Cγ, where Cβ is more active than Cγ.

► Methane cracking over Ni catalysts supported on porous and non-porous alumina.
► 1st cracking step: the non-porous catalyst performed better than the porous one.
► Non-porous catalyst deactivated quickly after 1st cracking/regeneration cycle.
►  Performance over porous catalyst increased after the 1st cycle.
► Porous catalyst sustained activity after 24 cracking/regeneration cycles.