A promising bimetallic 17 wt % Ni3Fe catalyst supported on γ-Al2O3 was prepared via homogeneous deposition–precipitation for the application in the methanation of CO2 to gather more detailed insight into the structure and performance of the catalyst compared to state-of-the-art methanation systems. X-ray diffraction (XRD) analysis, detailed investigations using scanning transmission electron microscopy (STEM) combined with energy dispersive X-ray spectroscopy analysis (EDX) of single particles as well as larger areas, high-resolution transmission electron microscopy (HRTEM) imaging, temperature-programmed reduction (H2-TPR), and in-depth interpretation of Raman bands led to the conclusion that a high fraction of the Ni and Fe formed the desired Ni3Fe alloy resulting in small and well-defined nanoparticles with 4 nm in size and a dispersion of 24%. For comparison, a monometallic catalyst with similar dispersion using the same preparation method and analysis was prepared. Using a fixed-bed reactor, the Ni3Fe catalyst showed better low-temperature performance compared to a monometallic Ni reference catalyst, especially at elevated pressures. Long-term experiments in a microchannel packed bed reactor under industrially relevant reaction conditions in competition with a commercial Ni-based methanation catalyst revealed an improved performance of the Ni3Fe system at 358 °C and 6 bar involving enhanced conversion of CO2 to 71%, selectivity to CH4 > 98%, and most notably a high stability. Deactivation occurred only at lower temperatures, which was related to carbon deposition due to an increased CO production. Kinetic measurements were compared with literature models derived for Ni/Al2O3 catalysts, which fit well but underestimate the performance of the Ni3Fe system, emphasizing the synergetic effect of Ni and Fe.

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Abstract:The methanation of CO 2 within the power-to-gas concept was investigated under fluctuating reaction conditions to gather detailed insight into the structural dynamics of the catalyst. A 10 wt % Ni/Al 2 O 3 catalyst with uniform 3.7 nm metal particles and a dispersion of 21% suitable to investigate structural changes also in a surface-sensitive way was prepared and characterized in detail. Operando quick-scanning X-ray absorption spectroscopy (XAS/QEXAFS) studies were performed to analyze the influence of 30 s and 300 s H 2 interruptions during the methanation of CO 2 in the presence of O 2 impurities (technical CO 2 ). These conditions represent the fluctuating supply of H 2 from renewable energies for the decentralized methanation. Short-term H 2 interruptions led to oxidation of the most reactive low-coordinated metallic Ni sites, which could not be re-reduced fully during the subsequent methanation cycle and accordingly caused deactivation. Detailed evaluation of the extended X-ray absorption fine structure (EXAFS) spectra showed surface oxidation/reduction processes, whereas the core of the Ni particles remained reduced. The 300-s H 2 interruptions resulted in bulk oxidation already after the first cycle and a more pronounced deactivation. These results clearly show the importance and opportunities of investigating the structural dynamics of catalysts to identify their mechanism, especially in power-to-chemicals processes using renewable H 2 .

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A novel nanoparticulate catalyst of copper (Cu) and ruthenium (Ru) was designed for low-temperature ammonia oxidation at near-stoichiometric mixtures using a bottom-up approach. A synergistic effect of the two metals was found. An optimum CuRu catalyst presents a reaction rate threefold higher than that for Ru and forty-fold higher than that for Cu. X-ray absorption spectroscopy suggests that in the most active catalyst Cu forms one or two monolayer thick patches on Ru and the catalysts are less active once 3D Cu islands form. The good performance of the tuned Cu/Ru catalyst is attributed to changes in the electronic structure, and thus the altered adsorption properties of the surface Cu sites.