Heterogeneous catalyst engineering ⇒ from stable and deactivation resistant to viable technical catalyst

Problem statement

Advances in heterogeneous catalyst “structure” are driven to improve their “function” or performance, i.e., activity, selectivity, and stability. Cooperative research is required to understand the structure and function relationships: developing new synthesis protocols for heterogeneous catalysts with unique surface properties, defined porosity, identification and understanding of catalytically active sites, reaction mechanisms, and finally, prediction and analysis of the processes using various computational tools.

Our group focuses on developing new catalyst formulations using innovative synthesis routes for various important heterogeneous catalysts. That includes thermal, electro, and bio-electro catalysis.

The active phase cannot be used directly in its final application or reactor for various reasons, including poor mechanical resistance, heat or mass transport, and fluidization features. We must mix the active phase with other ingredients in a matrix of binder and filler, while we shape it into a technical catalyst. We investigate new synthetic protocols for technical catalysis using spray drying and fluidized beds to cover the whole range of sizes. At the same time, we incorporate additional (unconventional) ingredients such as SiC to improve some features even further.

Goals

  • Technical catalyst I ⇒ spray drying and extrusion
  • Technical catalyst II ⇒ spray fluidized bed reactor
  • Technical catalyst III ⇒ electrospinning
  • Zeolite catalysts ⇒ with defined structure/porosity
  • Multi-metal (high entropy) alloy catalysts
  • MXene catalysts ⇒ single and multi-dimensional
  • Perovskite catalysts
  • Metal-organic framework (MOFs) catalysts
  • Supported metal/metal-oxide catalysts
  • Aerogel catalyst

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NiFeMnBaPr perovskite Pre-Catalysts for stable steam reforming of heavy crude oil

by Albuali, Mohamed, Ramos-Fernandez, Morlanes, Rendón-Patiño, Alahmadi, Bai, Castaño
Fuel Year: 2025 DOI: https://doi.org/10.1016/j.fuel.2025.134560

Abstract

This study evaluates the stability and activity of Pr0.5Ba0.5Mn0.8Ni0.15Fe0.05O3 perovskite pre-catalyst, demonstrating its capability to resist deactivation and produce hydrogen under the challenging conditions required for reforming heavy crude oil. Operating at 800 °C, the catalyst achieved an 88 % conversion, yielding a hydrogen-rich gas stream (54 mol% H2) with minimal pressure buildup, outperforming the “traditional” NiCoCeMgAl catalysts (stable for 3 h) by maintaining stability for 30 h. The catalyst resistance against carbon deposition and sulfur is enhanced through a unique composition, which enables efficient coke gasification and the formation of phases that keep the activity. These phases formed during the reaction (NiSx, NiC, Fe2O3, FeC, and MnOx) contribute to prolonged activity by releasing oxygen to react with carbonaceous deposits. Our work highlights the potential for hydrogen production from heavy crude oil and establishes a pathway for developing highly durable catalysts for industrial applications.

Keywords

HCE C2H