Steam Reforming of Liquid Hydrocarbon Boosted by a High-Performance and Durable Ni/NiAl2O4/Al2O3 Catalyst

Sep 29, 2026

Integrating solid oxide fuel cells (SOFC) with liquid-hydrocarbon steam reforming for hydrogen production is essential for SOFC industrialization and low-carbon objectives, requiring efficient reforming catalysts. This work designs a Ni/NiAl2O4/Al2O3 structured reforming catalyst and evaluates the effects of preparation and reduction temperatures. Optimal performance is achieved for calcination at 1000 °C and reduction at 600 °C, with exceptional anti-carbon-deposition behavior at 750 °C. Spinel catalysts show markedly improved stability versus lower-temperature supported catalysts, operating for 200 h without deactivation under 10 mL/g·h, S/C = 2.5, and 750 °C. XRD and SEM indicate that defective spinel structure and smaller Ni particles drive activity and coke resistance, while strong metal–support interaction governs stability, guiding highly stable catalyst design.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages9

Reading Time23 min

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Abstract

Introduction

Background: Fossil fuel emissions and SOFC need for hydrogen

Steam reforming and SR-SOFC integration

Catalysts for steam reforming and role of Ni/Al2O3

Challenges: metal sintering and carbon deposition

This article is licensed under CC-BY-NC-ND 4.0 [http://pubs.acs.org/journal/acsodf](http://pubs.acs.org/journal/acsodf) Article Steam Reforming of Liquid Hydrocarbon Boosted by a HighPerformance and Durable Ni/NiAl2O4/Al2O3 Catalyst Zesong Wang, Ying Yang, Zihao Liao, Dingrong Ou, Peng Dai, Keying Feng, Binbin He, Qunwei Guo, * Lu Zou, * Jian Pu, and Bo Chi Cite This: ACS Omega 2025, 10, 58647−58655 Read Online | | | | | | --- | --- | --- | --- | | ACCESS | Metrics & More | | Article Recommendations | ABSTRACT: Integrating SOFC with liquid hydrocarbon fuel reforming for hydrogen production is crucial for SOFC industrialization and achieving low-carbon goals, which calls for efficient reforming catalysts. In this study, a Ni/NiAl2O4/Al2O3 structured reforming catalyst is designed, and the impact of various preparation and reduction temperatures on the catalyst is investigated. The testing results revealed that the catalyst calcined at 1000 °C exhibited optimal catalytic activity when reduced at 600 °C while demonstrating exceptional resistance to carbon deposition at a reduction temperature of 750 °C. Additionally, compared to supported catalysts calcined at lower temperatures, spinel catalysts exhibit significantly enhanced stability and can operate stably for 200 h under the conditions of 10 mL/g·h, S/C = 2.5, and 750 °C, showing no signs of deactivation. The catalyst was characterized through combined XRD and SEM analysis, revealing that the enhancement in catalytic activity and resistance to carbon deposition is primarily attributed to the defective spinel structure and the smaller Ni particles. Meanwhile, the stability is related to the strong metal−support interaction facilitated by the spinel structure, which provides valuable insights and directions for the design of highly stable catalysts. 1. INTRODUCTION The current society’s heavy reliance on fossil fuels and the energy utilization method based on internal combustion engines have significantly increased pollutant and CO2 emissions, exacerbating air pollution and the greenhouse effect in recent years. In response to these issues, various countries have proposed corresponding emission reduction plans.1 Solid oxide fuel cells (SOFCs) represent a promising approach for energy utilization, as they directly convert chemical energy into electrical energy through electrochemical reactions, offering higher theoretical efficiency.2 However, the current development of SOFCs is constrained by the inadequate infrastructure for hydrogen, which is primarily used as the fuel of SOFCs.3 Steam reforming (SR) can convert common liquid fuels such as diesel or gasoline into gaseous fuels rich in hydrogen, which can then be utilized in SOFCs.4,5 Furthermore, due to their high operating temperatures, SOFCs can also utilize fuels such as CO and CH4 present in the reformate gas. Additionally, the waste heat generated by SOFCs can provide heat for thereforming process, enabling more efficient energy utilization.6 However, the development of highly efficient reforming catalysts plays a pivotal role before the widespread application of SR-SOFC. Supported oxides are the most commonly used catalysts in steam reforming for hydrogen production, where highly dispersed and nanosized metal particles can be achieved by loading active metals onto metal supports with high specific surface areas. Transition metals such as Ni and Co, as well as precious metals like Pt, Rh, and Ru, are commonly used as active metals.7−9 Compared to precious metals, transition metals Ni and Co are abundant, widely sourced, and low-cost, particularly Ni, which exhibits catalytic activity comparable to that of precious metals at the nanoscale, making it have a high potential as an active metal material. Al2O3 is a porous support material that is frequently employed, with a specific surface area typically exceeding 150 m2/g. It also exhibits high sintering resistance, maintaining a high spec

FAQs

How does the study optimize the catalyst preparation and reduction conditions?

The work compares catalysts prepared and reduced at different temperatures. The best catalytic activity occurs for calcination at 1000 °C and reduction at 600 °C, while carbon-deposition resistance is best when reduced at 750 °C.

What stability performance is reported under realistic testing conditions?

The spinel-structured catalyst maintains stable operation for 200 h without deactivation under 10 mL/g·h, S/C = 2.5, and 750 °C.

What are the main mechanisms behind improved activity, carbon resistance, and stability?

XRD and SEM results attribute the activity and anti-carbon-deposition behavior primarily to a defective spinel structure and smaller Ni particles. Stability is linked to strong metal–support interaction promoted by the spinel structure.

Sep 29, 2026

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