Catalyst optimization strategies

In order to acquire competitive catalytic performance with noble metals, a series of optimization procedures need to be carried out over cobalt based catalysts. The significance of support was first explored by Haga et al. [59] indicating that Co/ Al2O3 shows more promising activity than SiO2, C, ZrO2, and MgO. A relatively systematic investigation of the effect of supports was performed by Llorca and his coworkers [65]. Among the supports of CeO2, Sm2O3, MgO, Al2O3, SiO2, TiO2, ZnO, La2O3, V2O5 reported in this study, ZnO was ranked the best.

Recently mixed metal oxides have been employed as the support to improve the behavior of single metal oxides by doping one or more additional components into the original support lattice. For instance, in the implementation of Ce1-xZrxO2, as the washcoat material in three­way catalysts, support combines the oxygen mobility of CeO2 and thermal tolerance of ZrO2 [66-69]. The introduction of Ca creates oxygen vacancies, which is beneficial for the enhancement of oxygen mobility [70, 71]. Besides, the perovskite-type oxides such as LaAlO3, SrTiO3, and BaTiO3 have been used as the support for BESR catalysts due to their highly labile lattice oxygen [72, 73].

The cobalt precursor was proved by several authors [60, 74, 75] to have prominent effect on catalytic performance, which was proposed to be related to the cobalt dispersion. From the comparison between several precursor candidates, the one complexed with organic functional groups gave higher dispersion, which could be attributed to its isolation effect on the nearby Co atoms from agglomeration. It has been accepted that the active site during bio-ethanol steam reforming is related to the metal cobalt [76], that is, the higher the percentage of the cobalt that is available, the better the catalytic performance for BESR. Therefore, the improvement of cobalt dispersion will benefit the enhancement of corresponding catalytic activity.

It is expectable that cobalt loading has direct impact on the cobalt dispersion in the final catalyst. From the studies performed over Ni-based catalysts [53, 77], there exists an optimal loading, which can obtain the highest metal dispersion, through increasing the metal loading while avoiding metal sintering occurring at high loading due to the agglomeration of nearby metal atoms during thermal treatment. To the best of our knowledge, there is no systematic research of the effect of cobalt loading on its catalytic performance during BESR. Therefore, executing such a study can provide us better control of the catalyst optimization.

The impregnation medium is expected to have influence on the diffusion of cobalt precursor during impregnation and redistribution of cobalt atoms during the subsequent thermal treatment, which is shown by the experimental observations over Co/SiO2 [78]. The smaller Co3O4 crystallite size obtained for samples using ethanol rather than water as impregnation solvent is attributed to the formation of ethoxyl groups on silica and/or Co3O4 surface during impregnation which hindered the sintering of Co3O4 by physically interfering during the thermal decomposition of nitrates. As a result, a higher percentage dispersion of cobalt metal was achieved from reduction of smaller crystallites of Co3O4. In addition, further sintering of cobalt metal during reduction might be hindered by ethoxyl groups as well. Since the cobalt dispersion is closely correlated to the activity during BESR as described above, this effect needs to be further investigated.

It was reported by Enache et al. [79] and Ruckenstein [80] in their studies of cobalt-based catalysts for Fischer-Tropsch reaction that the parameters used in the sample heat treatment before being charged for reaction play a significant role on the cobalt dispersion and in turn catalytic activity. Thus the synthesis parameters during calcination and reduction need to be explored to optimize the catalytic performance.

The promotion effect of alkali metal addition has been observed separately by Llorca et al., and Galetti et al. [63, 64, 81]. The hydrogen yield enhancement and carbon deposition inhibition showed the improvement of catalytic performance even when a small amount of Na and K (~0.7 wt. %) was introduced. As an inexpensive additive, this promising modification should be further explored.

Similar to Ni catalysts, promotion effect has also been evidenced over the samples with the formation of metallic alloy. According to the results published so far, the second active metal in addition to Co can be generally categorized as noble metals (e. g., Rh [82] and Ru [83-85]) and non-noble metals (e. g., Ni, Cu [63, 86], Fe, and Mn [87]). The integration of each metal specialized in different functions might be responsible for the synergetic interaction on the improvement of catalytic performance. The non-noble metal additives also merit further investigation.

Not only the modifications to the formulation of catalyst system, but also the preparation methods can impact the catalytic performance. Versatile synthesis strategies have been developed for obtaining catalysts with high performance during BESR. Incipient wetness impregnation (IWI) [88-91], wet impregnation [84, 92, 93], sol-gel (SG) [94, 95], and co­precipitation (CP) [63, 64, 86, 87] are the most commonly utilized methods, each of which has its own advantages and disadvantages. Impregnation is the most convenient method to be scaled up, for manufacturing. However, nonhomogeneous distribution of the metal precursor is the biggest issue associated with the impregnation method, leading to metal agglomeration, one of the reasons which contribute to catalyst deactivation. On the contrary, it is easier for SG and CP to achieve homogeneous dispersion of active metal. However, the synthesis procedure of SG and CP is more complicated compared with that of impregnation, leading to poor reproducibility between various batches. Also, since most of the active metal atoms are embedded in the matrix of support, resulting in less exposure of active metal on the sample surface, SG and CP prepared samples are more stable but less active than those prepared by impregnation. In addition, several novel preparation protocols such as hydrothermal [96], solvothermal [97], and microemulsion [98] have been developed to control the sample particle size and morphology which have been shown to be highly relevant to catalytic activity. On the other hand, most of the newly developed methods mentioned involve the employment of organic solvents, which could be harmful to the surroundings. Although all the preparation techniques documented up to now supply abundant resources to start with, the establishment of an appropriate method balancing low cost, easy operation, and environmental benignancy is important to be researched.