Catalyst overview

In order to achieve equilibrated or even higher hydrogen yield especially at lower temperatures, catalytic bio-ethanol steam reforming (BESR) has been studied increasingly in recent years. More than three hundreds papers have been devoted to this field within the last two decades. The catalyst systems developed in these studies can be generally classified into two categories, i. e., supported noble and non-noble metal catalysts [32, 33]. However, based on the results reported in the literature, there is no commonly accepted optimal catalyst system which has excellent performance as well as low cost.

The noble metal catalysts such as Rh, Ru, Pd, Pt, Re, Au, and Ir [34-39] have been extensively investigated for BESR, which exhibit promising catalytic activity within a wide range of temperatures (350 oC~800 oC) and gas hourly space velocities (GHSV: 5,000~300,000 h-1). The outstanding catalytic performance experienced by noble metal catalysts might be closely related to its remarkable capability in C-C bond cleavage [40]. Among the noble metal catalysts reported so far, it is evidenced [41-44] that Rh is generally more effective than other noble metals in terms of ethanol conversion and hydrogen production. Diagne et al. [45] claimed that up to 5.7 mol H2 can be produced per mol ethanol (equal to 95 % H2 yield) at 350 oC-450 oC over CeO2-ZrO2 supported Rh catalyst. However, although the metal loading is relatively low (1~5 wt.%) compared with its non-noble counterparts (10~15 wt.%), the extremely high unit price still limits its wide-scale industrial applications.

As a less expensive alternative way to address the cost issue, increasing attention has been focused on the development of non-noble metal catalysts. According to the publications documented so far, the efforts are mainly focused on the Cu, Ni, and Co based catalyst systems, especially supported Ni catalysts. As typical transition metals, the active outer layer electrons and associated valence states determine their identities as the candidates for BESR. Similar with noble metals, Ni also works well as it favors C-C rupture. Based on the observations reported by several authors [38, 43, 46], the non-precious metals are less reactive than noble metal supported samples. Specifically, Rh sites resulted to be 3.7 and 5.8 times more active than Co and Ni, respectively, supported by MgO under the reaction conditions used in [43]. For obtaining the same reactivity (H2 yield > 95 %), much higher temperatures (650 oC) have to be employed [43, 47] over Ni catalysts. Furthermore, the non­noble metals are more prone to be deactivated due to sintering and coking compared with Rh. In order to achieve the comparable catalytic performance with noble metals, the formulation modifications of non-noble metal catalyst systems are worth studying for future commercialization. After summarizing the papers dedicated to investigation of various supports, ZnO and La2O3 seem more promising than MgO, Y2O3, and Al2O3 in terms of activity and stability [48, 49]. The basicity of sample surface has been evidenced crucial to improve its stability by adding La2O3 into the Al2O3 support aiming to neutralize the acidic sites present on the Al2O3 surface [50]. The addition of alkali metals (e. g., Na, K) to Ni/MgO has been observed to depress the deactivation occurrence by preventing Ni sintering [51]. It is worth noting that the recent interests on Ni catalysts seem to be transferred to CeO2 and ZrO2 supported samples, which could be ascribed to its well-known oxygen mobility, oxygen storage capability (OSC), and thermal stability [52-55], in turn improving coke — resistance. In addition, the synergetic effects become notable leading to better catalytic performance (activity, selectivity, and stability) when the second component (Cu) is incorporated into the Ni catalysts indicated by the work performed by Fierro et al., Marino et al., and Velu et al. [56-58]. They believe that the introduction of Cu might favor the dehydrogenation of ethanol to acetaldehyde, one of the important surface reaction intermediates during BESR. Compared with Ni based catalysts, cobalt samples have been less studied as catalysts for BESR. However, recent years have witnessed a significant increase in publications focusing on the development of Co-based catalysts, among which is the pioneering work by Haga et al. [59, 60]. Then Llorca et al. reported the promising results that 5.1 mol of H2 can be produced per mol of reacted ethanol over Co/ZnO sample [61]. Although the reaction condition is slightly unrealistic for industrial applications, this study proved that cobalt is also efficient in C-C bond breakage [62]. Neither copper nor nickel alone supported on zinc oxide appears to have as good reactivity and stability as that of its Co counterpart for hydrogen production under the same reaction conditions [63, 64]. After thorough investigation of the product distribution at various temperatures, it was indicated that the copper sample prefers dehydrogenation of ethanol into acetaldehyde but the reforming reaction does not further progress significantly into H2 and COx. On the other hand, the nickel sample favors the decomposition reaction of ethanol to CH4 and COx, accounting for the lower H2 yield at lower temperatures. Only at high temperatures can the methane production be lowered through steam-reforming. Moreover, Co catalysts have been applied in the Fischer-Tropsch to generate liquid hydrocarbons for more than 80 years. The knowledge accumulated during the study of Co based catalyst systems provides a good starting point. With these encouraging initial data, cobalt catalysts merit to be studied extensively as an alternative solution for reducing the cost from usage of noble metals.