Progresses in the Preparation of Coke Resistant Ni-based Catalyst for Steam and CO2 Reforming of Methane

Steam reforming of methane is an extremely important process for the hydrogen and syngas production. Nickel-based catalysts have been extensively employed in the industrial process of steam reforming because of their high activity, low cost, and the plentiful supply of Nickel. Nickel-based catalysts have also shown high activity for CO2 reforming of methane, which has been considered as a good option, with consumption of a significant amount of carbon dioxide. However, a major challenge is that Ni catalysts have a high thermodynamic potential for coke formation during reforming reactions. For steam reforming, coke formation induces deactivation of the catalyst, especially if the carbon forms as carbon filaments. The filamentous carbon material has a high mechanical strength and can cause mechanical deformation of the catalyst. For CO2 reforming, coke formation over Ni catalyst is even more serious and leads to rapid deactivation of the catalyst. It is highly desired to design and synthesize a coke resistant Ni catalyst not only for reforming of methane, but also for reforming of other hydrocarbons (including biomass derived hydrocarbons). Herein we summarize the very recent progresses in the design, synthesis, and characterization of coke resistant Ni catalysts for steam and CO2 reforming of methane. The progresses in the use of promoters, in the effect of supporting materials and in the preparation methods have been discussed. The thermal stability, regeneration, and future development of coke resistant Ni catalysts for these processes are also briefly addressed.