Improvement of coke resistance of Ni/Al 2 O 3 catalyst in CH 4 /CO 2 reforming by ZrO2 addition
Production of syngas from steam reforming and CO removal with water gas shift reaction over...
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i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 3
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Production of syngas from steam reforming andCO removal with water gas shift reaction overnanosized Zr0.95Ru0.05O2Ld solid solution
Vijay M. Shinde, Giridhar Madras*
Department of Chemical Engineering, Indian Institute of Science, Bangalore 560 012, India
a r t i c l e i n f o
Article history:
Received 29 May 2013
Received in revised form
8 August 2013
Accepted 15 August 2013
Available online 14 September 2013
Keywords:
Steam reforming
Hydrogen production
CO removal
Water gas shift
Tetragonal ZrO2
* Corresponding author. Tel.: þ91 80 2293232E-mail addresses: [email protected]
0360-3199/$ e see front matter Copyright ªhttp://dx.doi.org/10.1016/j.ijhydene.2013.08.0
a b s t r a c t
This study presents the synthesis, characterization, and kinetics of steam reforming of
methane and water gas shift (WGS) reactions over highly active and coke resistant
Zr0.95Ru0.05O2�d. The catalyst showed high activity at low temperatures for both the re-
actions. For WGS reaction, 99% conversion of CO with 100% H2 selectivity was observed
below 290 �C. The detailed kinetic studies including influence of gas phase product species,
effect of temperature and catalyst loading on the reaction rates have been investigated. For
the reforming reaction, the rate of reaction is first order in CH4 concentration and inde-
pendent of CO and H2O concentration. This indicates that the adsorptive dissociation of
CH4 is the rate determining step. The catalyst also showed excellent coke resistance even
under a stoichiometric steam/carbon ratio. A lack of CO methanation activity is an
important finding of present study and this is attributed to the ionic nature of Ru species.
The associative mechanism involving the surface formate as an intermediate was used to
correlate experimental data.
Copyright ª 2013, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights
reserved.
1. Introduction whiskers even at very low S/C ratios [4]. Among these noble
There is renewed interest in hydrogen production due to ad-
vances in fuel cell technology, which is an efficient way of
extracting energy fromhydrogen [1,2]. The steam reforming of
natural gas is the most economical and efficient catalytic
process for the production of hydrogen. Industrially, this re-
action is catalyzed over nickel supported Al2O3 catalyst
around 850 �C with steam to carbon (S/C) molar ratio in the
range of 2e5 [3,4]. The high temperature and low S/C ratio
(<1.4) result in sintering and deactivation of catalyst mainly
due to coke deposition via cracking of methane [5]. However,
noble metals (Ru, Rh, Pd, Ir and Pt) over various supports are
highly active and more resistant to the formation of carbon
1; fax: þ91 80 23601310..ernet.in, giridharmadras2013, Hydrogen Energy P70
metals, Ru and Rh have been reported to be the most active
catalysts and the propensity of deposited carbon decreases in
the order of Ni [ Rh > Ir w Ru w Pd at 500 �C [6e8]. Further,
Ru is cheaper that Rh and, therefore, it is desirable to explore
the activity of Ru based catalysts for steam reforming
reaction.
The reformer stream contains 8e15 vol% of CO depending
on the operating conditions and this stream cannot be directly
sent to the polymer-electrolyte fuel cell (PEFC). At high CO
concentration, the adsorption of CO on the noble electrode
takes place irreversibly and the performance of the fuel cell is
affected by this phenomenon. Therefore, CO needs to be
removed below 20 ppm in order tomake it suitable for fuel cell
@gmail.com (G. Madras).ublications, LLC. Published by Elsevier Ltd. All rights reserved.
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i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 313962
application. Thus, the water gas shift (WGS) is an integral
component of fuel processing for fuel cell applications, which
not only reduces the CO content but also enriches the
hydrogen content. The WGS reaction is slightly exothermic.
Therefore, the reaction is equilibrium limited at high tem-
peratures and kinetically limited at low temperatures.
Therefore, the WGS reaction is usually carried out in two
stages: high temperature shift (350e500 �C) with Fe2O3/Cr2O3
catalyst and low temperature shift (200e250 �C) with Cu/ZnO/
Al2O3 catalyst [9]. However, these catalysts are not suitable for
fuel cell applications because of their pyrophoricity, sensi-
tivity to start-up/shut-down cycles, lengthy and cumbersome
activation procedure [10,11].
On the other hand, noble metal based catalysts, mainly Pt
supported on ceria or ceria based mixed oxides have exten-
sively been studied as promising low temperature shift cata-
lysts [12,13]. Au supported on reducible oxides such as CeO2,
TiO2, Fe2O3 have shown remarkable activity for WGS reaction
[14]. However, there is uncertainty about the feasibility of
these catalysts for practical applications [15]. Further, Pt
supported ceria catalysts are vulnerable to deactivation with
time on stream mainly due to over reduction of support, sin-
tering, loss of surface area and the formation of stable surface
carbonate [16,17 and references therein].
ZrO2 offers few advantages over the ceria support due to its
high thermal stability and unique acidic and basic properties
[18]. Previously, we have studied WGS reaction over combus-
tion synthesized zirconia and Pt substituted ZrO2was found to
be highly active [19]. In another study, excellent activity and
stability was observed over Pt/ZrO2 catalyst due to the lack of
Pt sintering [20]. The polymorphic structure dependent ac-
tivity has also been studied for WGS reaction and the tetrag-
onal phase of ZrO2 was reported to be more active phase than
the monoclinic phase [21]. The difference between activities
was attributed to the high reactivity of the hydroxyl groups
over tetragonal phase [22]. Further, Ru supported catalysts are
also active forWGS reaction. However, very little attention has
been paid to examine the activity of the Ru based catalysts due
to the drawback of CO methanation under WGS conditions
[23]. Previously, we have shown that the Ru based catalysts, if
developed properly, can suppress the CO Methanation reac-
tion [24]. Therefore, it is very interesting to investigate the
WGS reaction over Ru supported tetragonal ZrO2.
Coke deposition, sintering and agglomeration of the active
metal are the main causes of catalyst deactivation in steam
reforming reaction [25]. Therefore, an intimate contact and
strong metal support interaction between metal and support
is necessary for the development of stable catalyst [5]. For
example, the high stability of Rh based catalyst depends on
the interaction between Rh and oxygen of the support, which
anchors the Rh particle on the support and inhibits noble
metal sintering [25]. The importance of strong metal support
interaction between the noble metal (Au or Pt) and the oxygen
of ceria has also been demonstrated for WGS reaction and it
has been claimed that the ionically dispersed Au or Pt are the
most active species for WGS reaction [26e29]. Further, the
activity of the catalyst depends on the dispersion of active
phase. The fine dispersion not only increases unsaturation of
the surface metal atoms but also provides more steps and
kinks sites on the surface. It has been reported that the energy
barrier for CH4 dissociation, which is considered to be a rate
determining step decreases with increasing coordinative
unsaturation of the surface metal atoms. It means that the
rate of reaction depends on the extent of metal dispersion and
interaction with the support [30]. Therefore, high dispersion
and ionic nature of active phase are essential for high activity
and stability.
The ionic substitution of metals in the lattice of metal ox-
ides offers advantages such as complete metal dispersion
within an oxide support, high oxygen storage and release, and
redox exchange between substituted metal and metal oxide
[31]. Further, ionic substitution of metal also creates oxide ion
vacancies and activation of molecules such as CH4, CO and
H2O over oxide vacancies have been demonstrated [30]. The
high rate of reaction over ionic catalysts compared to the
same metal impregnated oxide for various reactions like CO
oxidation, NOx reduction andWGS reaction has been reported
in literature [32,33]. Therefore, ionic substitution of metal in
support could be another alternative to maximize the metal
support interactions.
This study reports the synthesis and characterization of
nanosized Zr0.95Ru0.05O2�d solid solution by low temperature
sonication method using diethylenetriamine (DETA) as a
complexing agent. The performance of the solid solution was
investigated for both the steam reforming andWGS reactions.
The detailed kinetic studies including influence of gas phase
product species, effect of temperature and catalyst loading on
the reaction rates have been investigated. The catalyst sta-
bility and resistance towards coke deposition were also
investigated for steam reforming of CH4.
2. Experimental
2.1. Synthesis and characterization
Nanostructured Zr0.95Ru0.05O2�d solid solution was synthe-
sized using a sonochemical method at room temperature.
Reagent grade zirconyl nitrate [ZrO(NO3)2, Thomas Baker,
India], ruthenium chloride [RuCl3, Spectrochem, India],
diethylenetriamine (DETA) [(C4H13N3) S.D Fine, India] were
used without further purification. In a typical experiment, 5 g
of ZrO(NO3)2 and 0.5 g of RuCl3 were dissolved in 100 ml of
deionized water. 5 ml of DETA was then added to the solution
and the solution turned to gel immediately. The resulting gel
was irradiated with high intensity ultrasound radiation (Ti
horn, 20 kHz, 125 W/cm2 at 60% efficiency) for 4 h. The tem-
perature during the sonication increased to 60 �C. After soni-cation, the product was centrifuged, washed repeatedly with
water-ethanol mixture, and then dried in hot air oven at
120 �C for 3 h. The solid product was further calcined at 450 �Cfor 30 min to remove (if any) the residual of chloride/nitrates
and the dry powder product is termed as “as-prepared com-
pound”. 5 at% Ru impregnated on ZrO2 was also prepared for
comparison. RuCl3 corresponding to 5 at% was added to an
aqueous dispersion of ZrO2 (synthesized by sonication
method) and reduced by hydrazine hydrate (99%, S.D Fine,
India). The product was then washed with water-ethanol
mixture, filtered, and dried at 110 �C for 5 h. Finally, the
product was heated at 450 �C before the reaction.
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i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 3 13963
The crystal structure of the synthesized compound was
studied by X-ray diffraction (XRD) on Philips X’Pert Diffrac-
tometer operated at 40 kV and 30 mA with Cu Ka radiation
(l ¼ 1.54056 �A) in the 2q range of 20e80� at 0.02� min�1. Theprofile fitting, lattice parameter refinement and microstruc-
ture analysiswere performed on pure tetragonal phase of ZrO2
using JANA 2000 program suite. The size and morphology of
the synthesized compound were observed by transmission
electron microscopy (TEM) on a FEI Technai 20 operating at
200 kV. The powdered sample was ultrasonically dispersed in
ethanol and dropped onto the carbon coated Cu grid (300
mesh). Energy dispersive X-ray (EDX) analysis was also carried
out on the same instrument with a fine probe. Raman spectra
were recorded on a NXR-FT Raman module (Thermo Scienti-
fic, USA) with the spectrum resolution of 4 cm�1 equipped
with Ge detector and Nd: YVO4 laser. The spectra of the
sample before and after the reaction were recorded at room
temperature. X-ray photoemission spectra (XPS) were recor-
ded in a Thermo Scientific Multilab 2000 equipped with Al Ka
radiations source (1486.8 eV). All spectra were charge cor-
rected with the C (1s) peak observed at 285 eV and they are
accurate within �0.1 eV. BET surface area of the sample was
measured with a Quantachrome NOVA 1000 gas adsorption
analyzer. Before the measurement, the sample was degassed
at 150 �C for 5 h under vacuum.
2.2. Catalytic activity measurements
Catalytic tests were performed in a fixed bed continuous flow
reactor in a packed bed quartz reactor tube (30 cm in length
and 0.4 cm of ID) under atmospheric pressure using 100 mg of
catalyst (80e100 mesh) diluted with an inert glass beads. The
reactor is fixed in a tubular electrical furnace and the tem-
perature of catalyst bed was measured by a K type thermo-
couple inserted in the middle of packed bed. Prior to the
activity test, the catalyst was reduced at 650 �C for 2 h under a
mixture of 5% H2 in N2 at a flow rate of 50 ml/min. The steam
reforming reaction was carried out with the gas mixture
consisting of 3 vol% of CH4 and the balance wasmade up of N2
keeping the total flow rate to 100 ml/min. All experiments
were performed at the gas hourly space velocity of 80,000 h�1
(on dry basis). Water was pumped at a constant flow rate of
0.08 ml/min to the evaporator using HPLC pump (Waters 410)
and the generated steam (3 ml/min) was mixed with the re-
action mixture. A stream trap was placed to condense the
surplus steam at the downstream of the reactor. The dry
product gas mixture was analyzed by a gas chromatograph
equipped with a FID (incorporating a methanator) and TCD
detectors. Hayesep-A columnwas used to separatemixture of
CH4, CO and CO2 and amolecular sieve 5A columnwas used to
separates mixture of H2, and N2. The reforming reaction was
carried out isothermally at several temperatures. Methane
conversion and CO selectivity in steam reforming were
calculated
CH4 conversion ð%Þ ¼�CCO þ CCO2
��CCO þ CCH4 þ CCO2
�� 100 (1)
CO selectivity ð%Þ ¼ CCO�CCO þ CCO2
�� 100 (2)
C is the concentration of each component in the effluent
stream. The rate of formation of (CO þ CO2) was almost equal
to the rate of disappearance of CH4 indicating the rate of
carbon deposition was negligible.
The catalytic activity of Zr0.95Ru0.05O2�d for WGS reaction
wasmeasured at atmospheric pressure in terms of percentage
of CO conversion. The WGS reaction was carried in the same
reactor employing 2 vol% CO balanced of N2 with a total gas
flow of 100 ml/min over 250 mg catalyst in the range of
140e500 �C. The gas hourly space velocity of 60,000 h�1 (on dry
basis) was kept constant for all experiments. The influence of
H2O/CO ratio on CO conversion was also studied and it was
found that at a given temperature, CO conversion was
increased with H2O concentration. However, at higher H2O
concentration (>flow rate 5 ml/min), the conversions
remained independent of H2O concentration. Therefore, the
flow rate of water vapor was maintained at 5 ml/min. Further
details about the experimental setup can be found elsewhere
[34].
3. Results and discussion
3.1. Structural studies
XRD patterns of the as-synthesized compound are shown in
Fig. 1. All the peaks were indexed to tetragonal structure of
ZrO2 (space group: P42/nmc) and no diffraction peak corre-
sponding to Zr-DETA complex or Ru-DETA complex or Ru
metal or RuO2 were observed. The y scale of the XRD patterns
was also magnified 10 times in the range of 30e50� and no
peaks either due to Ru or RuO2 were found. This implies that
the substitution of Ru metal in the ZrO2 forming a single solid
solution can be represented by the formula Zr0.95Ru0.05O2�d.The changes in the lattice parameter on the substitution of Ru
metal in ZrO2 were obtained by profile refining using JANA
2000 suite program. The Pseudo-Voigt and Legendre poly-
nomial (no of terms ¼ 15) were used as peak width and
background function, respectively. The observed, calculated
and difference XRD patterns of the compound are shown in
Fig. 1. The satisfactory values of the reliability parameters Rp
and Rwp were obtained by fitting the XRD patterns to the
tetragonal phase while poor correlation was obtained by
fitting the XRD patterns to the monoclinic phase. The lattice
parameter, crystallite size and the reliability parameters are
summarized in Table 1. A slight decrease in the lattice
parameter of Zr0.95Ru0.05O2�d compared to unsubstituted ZrO2
also confirms ionic substitution. The broad X-ray line width is
indicative of nanometer sized crystallites and the average
crystallite size was determined to be 8 nm using the Scherrer
equation with taking into account the full width at half-
maximum (FWHM) of the most intense peak.
The XRD pattern of Zr0.95Ru0.05O2�d was also recorded after
3 cycles of WGS reaction and profile refined XRD patterns is
shown in Fig. 1(b). The XRD patterns are identical to the as-
synthesized compound and could be indexed to the parent
tetragonal structure of ZrO2. Diffraction peaks due either Ru or
RuO2 were not observed in spent catalyst. Therefore,
Zr0.95Ru0.05O2�d compound retained its structure even after 3
cycles of WGS reaction.
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Fig. 1 e Profile refined XRD patterns for Zr0.95Ru0.05O2Ld (a) as-synthesized (b) after 3 cycles of WGS reaction, respectively.
i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 313964
Due to the presence of nanocrystals, XRD peaks are broad
and it is difficult to distinguish the tetragonal and cubic
structure of ZrO2 on the basis of XRD only. Therefore, the
crystal structure of Zr0.95Ru0.05O2�d was also confirmed using
FT-Raman spectroscopy. Fig. 2 shows the FT-Raman spectra of
the compound before and after the reaction. Peaks mainly
observed at 145, and 260 cm�1 are characteristic of tetragonal
phase and a single peak at 490 cm�1 is the characteristic of
cubic phase, respectively [35]. No strong band was observed at
w260 cm�1, and it can be due to changes in disorder of the
oxygen sublattice of Ru stabilized ZrO2 [35]. However, the
presence of the peak near 145 cm�1 and the absence of the
peak near 490 cm�1 confirm that Zr0.95Ru0.05O2�d crystallizes in
tetragonal structure with a space group of P42/nmc.
Bright field and high resolution (HRTEM) images of
Zr0.95Ru0.05O2�d are given in Fig. 3. The bright field image
shows that the average particle size is w9 nm, which is in
close agreement with the size determined by XRD. Selected
area electron diffraction pattern (see inset of Fig. 3(a)) clearly
shows high crystalline nature of Zr0.95Ru0.05O2�d nanoparticlesand the ring patterns can be assigned to tetragonal structure
of ZrO2. The absence of the rings either due to Ru or RuO2
confirms the formation of the single phase solid solution.
Further, HRTEM image (see Fig. 3(b)) indicates the presence of
many nanocrystals showing (111) lattice fringes of tetragonal
ZrO2. The energy dispersive X-ray (EDX) analysis was per-
formed on the same instrument and the analysis shows that
Zr and Ru are present in the compound with molar ratio of
0.96:0.04 which is close to the molar ratio taken during the
synthesis. Therefore, the combined studies of XRD, Raman
and TEM confirm the substitution of Ru in ZrO2 lattice. The
BET surface area for Zr0.95Ru0.05O2�d was found to be 104 m2/g.
Table 1 e Cell parameters of Zr0.95Ru0.05O2Ld obtained by profi
Compound Cell parameters (�A)
a/b c
Zr0.95Ru0.05O2�d (before reaction) 3.599 5.175
Zr0.95Ru0.05O2�d (after reaction) 3.606 5.176
The oxidation state of Ru and Zr in Zr0.95Ru0.05O2�d beforeand after WGS reaction was determined using XPS. The re-
sults of XPS were also used to understand the reaction
mechanism for the WGS reaction. All the binding energies
were adjusted to the C (1s) peak observed at 285 eV and this
was also verified with the oxygen peak observed at 530 eV.
Core level Ru (3d) spectra in Zr0.95Ru0.05O2�d before and after
the reaction are shown in Fig. 4(a). The binding energies of Ru
(3d) and C (1s) fall in the same range. Therefore, Ru (3p)
spectrum was also analyzed to assign the oxidation state of
Ru. The XPS spectrum was broad and therefore, the Ru (3d)
peak was de-convoluted to obtain C (1s), Ru (3d5/2) and Ru (3d3/
2) states. The binding energy of Ru (3d5/2) in Zr0.95Ru0.05O2�d is
slightly higher (0.4 eV) than the binding energy of Ru in RuO2,
indicating that the RueO distance and the location of the ox-
ygen atoms in Zr0.95Ru0.05O2�d is different from that of the Ru
ions in RuO2 [36]. The Ru (3p3/2) spectrum (not shown) also
showed slightly higher binding energy (463.1 eV) than that of
Ru (3p3/2) spectrum in RuO2.Therefore, it can be concluded
that that the Ru is in the 4þ oxidation state before the reac-
tion. The XPS spectrum of Ru (3d) afterWGS reaction is shown
in Fig. 4(a) and mixed oxidation state of Ru (Ru0 and Ru4þ) was
observed, which indicates that the Ru was in partially reduced
state after the reaction.
Fig. 4(b) shows the Zr (3d) photoelectron peak of
Zr0.95Ru0.05O2�d before and after the reaction. The binding
energy of Zr (3d5/2) and Zr (3d3/2) are 182.9 and 185.3 eV,
respectively and this corresponds to the 4þ state of Zr [37]. No
appreciable variation in the Zr spectrum was observed indi-
cating no reduction of Zr took place during the reaction.
Therefore, XPS results show that the participation of lattice
oxygen is not possible during the reaction and thiswas used to
le refinement.
Rp Rwp c2 Crystallite size (nm)
2.62 3.42 1.02 8
3.2 4.26 0.92 10
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Fig. 2 e FT-Raman spectra of Zr0.95Ru0.05O2Ld (a) before and
(b) after WGS reaction.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 3 13965
deduce the reaction mechanism for WGS reaction over
Zr0.95Ru0.05O2�d catalyst.
3.2. Steam reforming activity and kinetic study
Fig. 5 shows the influence of CH4 conversion and CO selec-
tivity over the catalyst. At low temperature, CO selectivity is
low, indicating a large contribution fromWGS. Nearly 93%CH4
conversion with 92% CO selectivity was observed at 700 �C.The rate of reaction and activation energy was determined by
performing experiments with different weights of the cata-
lyst. The reaction was carried out with composition of 3% CH4
and balance N2 with the total gas flow of 100 ml/min. The rate
of reaction was determined under absence of any transport
artifacts and the temperature of the reactor was varied such
that the differential reactor approach was maintained. The
following equation was used to calculate rate of reaction
rate ðrÞ ¼ F� xW¼ x
W=F(3)
Fig. 3 e (a) Bright field image and (b) HRTEM image of Zr0.95Ru0
where F is the flow of the gas in mol/s, W is the weight of the
catalyst in g and x is the fractional CH4 conversion. The vari-
ation ofW=FCH4 with the fractional conversion of CH4 is shown
in Fig. 6(a). The plot is linear up to 50% conversion and the
rates of reactionwere calculated at various temperatures from
the slope of the curve. The variation of rate of reaction as a
function of temperature is shown in Fig. 6(b). The apparent
activation energy of steam reformingwas calculated using the
Arrhenius plot and the corresponding plot is given in the inset
of Fig. 6(b). The activation energy for steam reforming reaction
was found to be 92 kJ/mol.
The effect of concentration of CH4, steam and CO on the
rate of reaction was investigated in a differential reactor with
50 mg of catalyst in the range of 400e550 �C under atmo-
spheric pressure. The total flow and space velocity was kept
constant for all experiments and reactor temperature was
varied in suchway that the total conversion of CH4was always
below 30%. The concentration of CH4 was varied from 1 to 4%
keeping the steam concentration constant at 2%. The con-
centration of steam was varied between 1 and 4% keeping the
concentration of CH4 constant at 2%. The rate of reaction in
the presence of CO was also examined independently. The
concentration of CO was varied between 0.25 and 0.75%
keeping the concentration of CH4 and steam constant at 2%.
Fig. 7(a) and (b) shows the variation of rate of CH4 conversion
as function of CH4 and steam concentrations, respectively.
The rate of reaction increases with CH4 concentration while
the rate of reaction is almost independent of steam concen-
tration. The order of reaction with respect to concentration of
CH4 was obtained by plotting ln(rate) versus ln ðCCH4 Þ and was
found to bew1 at all temperatures. The first order dependence
of the rate of reaction on concentration of CH4 and zero order
dependence on the steam concentration are also consistent
with the literature [25,38]. Therefore, it can be concluded that
the overall reaction is first order with respect to concentration
of CH4 and zero order with respect to steam concentration.
rCH4¼ kCCH4
(4)
Fig. 7(c) shows the effect of concentration of externally
added CO to the reaction mixture of CH4 and steam on the
rate of reaction. It can be seen from Fig. 7(c) that the rate of
reaction remains almost constant. This indicates that the
.05O2Ld with indexed electron diffraction in the inset of (a).
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Fig. 4 e Core level XPS of (a) Ru (3d) and (b) Zr (3d) in Zr0.95Ru0.05O2Ld before and after the reaction.
i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 313966
adsorption of CO over the catalyst surface is negligible and the
activation of CH4 was unaffected due to presence of fed CO.
This indicates that the activation of CH4 is the slowest step
compared to the activation of co-reactant molecules. These
results are consistent with the studies reported by Wei and
Iglesia for steam and dry reforming of methane over Ru sup-
ported on various supports [7,38]. The kinetic study over
Rh/ZrO2 at 400 �C also shows that the reaction is first order in
CH4 and the intrinsic activity did not depend on the steam to
carbon ratio [25].
The kinetics of CH4 steam reforming was studied exten-
sively over noble metals (Pt, Ru, and Rh), Ni-based catalysts.
However, the reaction mechanism has still remained contro-
versial and contradictory results can be found in the litera-
ture. This is mainly due to the nature, morphology of the
support and different experimental conditions. The kinetic
model including LangmuireHinshelwood, power laws, and
expressions based on microkinetic analysis were used to
describe the experimental data [6,39]. Generally, the dissoci-
ation ofmethane is considered to be the rate determining step
Fig. 5 e Variation of CO selectivity and CH4 conversion with
temperature for steam reforming reaction. The dotted line
shows the equilibrium conversion.
[4,40,41]. The mechanism involves the decomposition of CH4
to C* in a series of elementary steps followed by reaction be-
tween adsorbed oxygen derived from steam disassociation.
The subsequent H abstraction is much faster than the initial
CeH bond dissociation and this leads to low coverage of CHx*
intermediates on the surface [42]. DFT was used to investigate
the reaction pathways and kinetics over Ni (111). It was shown
that CH* is themost important intermediate and reactions like
CH*þ O*/ CHO* and CH*þOH*/ CHOH* are critical steps in
the mechanism [43,44]. In another study, it has been argued
that CHO species may be formed from CH2O or CH and O, and
dissociation of these result in CO and Hwhich then desorbs to
CO and H2 [43]. It should be noted that CH4 dissociation is still
the rate determining step. Further, the CHO* species was also
proposed as an intermediate for H2 induced CO dissociation
on nickel surface and the mechanism with this intermediate
showed the square root dependence on hydrogen pressure
[45]. However, it can be shown that if the CHO forms active
intermediates, the rate of steam reforming reaction should
decrease with addition of the CO/H2 in CH4eH2Omixture. Wei
et al. argued that this kind of step introduces intricacy in the
mechanism and these intermediates cannot be proved using
spectroscopic analysis due to their low steady state concen-
tration [7].
In another study, O2 assisted CH4 dissociation
(CH4* þ O* / CH3* þ OH*) was suggested to be a possible re-
action mechanism [46]. However, the energy barrier for O2
assisted CH4 dissociation is higher than unassisted CH4
dissociation [47]. Further, this would result in a more complex
reactionmechanism and the rate of reactionwould depend on
the surface concentration of O*. It means that the rate of re-
action should depend on concentration of co-reactants and
products which is contradictory to the present findings.
Therefore, O2 assisted CH4 dissociation is unlikely to initiate
the steam reforming reaction.
We studied the cracking of CH4 at 550 �C in absence of H2O
and only H2 was observed in the outlet stream via adsorptive
dissociation of CH4. Then, H2O vapor with N2 was passed over
the catalyst at the same temperature and CO and CO2 was
indeed observed. This shows that methane dissociates to
carbon and gaseous H2 on Rumetal. The gasification of carbon
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Fig. 6 e (a) Variation of fractional conversion of CH4 withW=FCH4 and (b) rate of reaction as function of temperature for steam
reforming reaction.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 3 13967
with O* species extracted from steam adsorption yields in the
formation of CO and CO2. Based on the qualitative trends
presented in this study, the following reaction stepswere used
to propose the reaction mechanism.
CH4 þ �/CðadsÞ þ 2H2 (5)
H2Oþ �4OðadsÞ þH2 (6)
CðadsÞ þOðadsÞ/COþ 2� (7)
This mechanism involves the following main steps (a)
dissociative adsorption of CH4 on Ru surface (Equation (5))
resulting in H2 and surface carbon, (b) dissociative adsorption
of steam on the Ru surface (Equation (6)) and (c) gasification of
the surface carbon by O* species extracted from steam
(Equation (7)). Based on the present results and available
literature, it was found that the rate of reaction was first order
with respect to CH4 concentration, which implies that the
overall reaction is controlled by dissociative adsorption of
CH4.
The stability and anti-coke property of the catalyst was
tested at 650 �C with 3% CH4 and balance of N2 keeping total
flow rate of 100 ml/min over 100 mg of catalyst (S/C ratio w1).
Fig. 8 shows the time on stream CH4 conversion and CO
selectivity for 24 h over the catalyst. No appreciable deacti-
vation of the catalyst was observed and conversion of CH4
(w74%) and selectivity of CO (w81%) remained nearly con-
stant over 24 h of testing. Therefore, the present catalyst is
highly active, stable and carbon resistant for the production of
syngas from CH4 under the low H2O/CH4 ratio. Thus, the
present catalyst is promising candidate in comparison with
the industrial reformer catalysts (mainly Ni based catalysts)
which deactivate rapidly due to deposition of coke on the
catalyst surface under low S/C ratio [48]. Further, the stability
of the catalyst under stoichiometric steam to carbon ratio (w1)
is important because it can avoid the extra cost associated
with steam recycling and results in syngas with H2/CO ratio
close to 2.5e2.8, which is desirable for methanol and
FischereTropsch synthesis.
3.3. WGS activity and kinetic study
WGS reaction was also carried over Zr0.95Ru0.05O2�d in the
temperature range of 140e500 �C with reaction mixture con-
sisting of 2% of CO and balance of N2 with the total flow rate
100 ml/min. Fig. 9(a) shows the variation of concentrations of
CO, CO2, H2 and CH4 with temperature. All the concentrations
were normalized by the initial concentration of CO and nearly
complete conversion (w99%) of CO with 100% selectivity to-
wards the hydrogen production was obtained below 290 �C.CO conversion increased in the temperature range of
140e400 �C and CO conversion decreased due to the reversible
nature of WGS reaction above 420 �C. The results also indicate
that CO conversion at 500 �C reached the equilibrium value
(98%) under the present feed gas conditions [49]. Notably, CO
methanation activity was not observed and CO2 and H2 were
the only products detected in the product stream (detection
limit <20 ppm).
Further, the unique role of ionic Ru substitution was also
investigated by performing WGS reaction over 5 at% Ru metal
impregnated ZrO2 catalyst. The gas mixture consisting of 2%
CO and balance of N2 with a total flow of 100 ml/min was
passed over 250 mg of catalyst. Fig. 9(b) shows the variation of
normalized concentrations of % CO, CO2 and H2 with tem-
perature. A nearly complete conversion of CO to CO2 (w99%)
was observed around 320 �C. The possible side product such as
methane was also observed above 320 �C. Therefore,
Zr0.95Ru0.05O2�d exhibits higher catalytic activity and selec-
tivity towards H2 production than those of Ru impregnated
ZrO2 catalyst and this is attributed to strong metal support
interactions and ionic nature of Ru in ZrO2.
The rate of reaction and activation energy forWGS reaction
over Zr0.95Ru0.05O2�d was determined by plotting fractional CO
conversion with W/FCO at different temperatures (see
Fig. 10(a)). The rate of reaction at various temperatures was
calculated from the slope of the curve. The total flow rate of
gas was kept constant at 100 ml/min and the weight of the
catalyst (W) was varied. The temperature of the reactor was
varied such that the differential reactor approach was
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Fig. 7 e (a) The effect of concentration of CH4 on the rate of
methane conversion at a constant CH2O [ 8.17 3 10L7 mol/
cm3 and (b) effect of H2O concentration on the rate of
methane conversion at a constant CCH4 [ 8.17 3 10L7 mol/
cm3 (c) effect of CO concentration on the rate of methane
conversion at a constant CCH4 [ 8.17 3 10L7 mol/cm3 and
CH2O [ 8.17 3 10L7 mol/cm3, respectively.
Fig. 8 e Time on steam methane conversion and CO
selectivity for steam reforming reaction.
i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 313968
maintained. The variation of rate of reaction with tempera-
ture is shown in Fig. 10(b) and it can be seen that the rate
of reaction is very high over Zr0.95Ru0.05O2�d catalyst. The
activation energy was calculated using Arrhenius equation
(see inset of Fig. 10(b)) and found to be 32 kJ/mol. The com-
parison of various catalysts in term of rate of reaction and
activation energy is given in Table 2. Therefore, the present
compound is promising in removing poisonous CO from the
reformate hydrogen for fuel cell applications.
A series of experiments were performed to investigate the
effect of concentration of CO and H2O on the rate of reaction.
All experiments were performed under isothermal conditions
with a differential reactor approach. Further, all experiments
ensured that the kinetic data is free from internal and external
mass transfer resistance. The dependence of the rates of re-
action on the reactant concentration was measured by
changing the concentration of one reactant by keeping the
concentration of other reactant constant. The composition of
COwas varied from1 to 3% at a constant steamcomposition of
2.75% and the composition of steamwas changed from 1 to 7%
at a constant CO composition of 2% (all on volume basis). The
total gas flow rate of the reaction mixture and loading of the
catalyst were kept constant at 100 ml/min and 50 mg,
respectively. The dependence of reaction rate on the con-
centration of CO and H2O at various temperatures is shown in
Fig. 11(a) and (b). At low concentration of CO, the rate of re-
action exhibits positive dependency on the concentration of
CO with the apparent order of reaction close to 1.
The rate of reaction shows a maximum at higher concen-
tration of CO,which indicates there is an optimumcoverage of
CO and steam on the catalyst surface. Therefore, it is expected
that CO and steam undergo competitive adsorption on the
catalyst for the same active sites under the present experi-
mental conditions. At high CO concentration, the coverage of
CO molecules on the catalyst surface is very high, which
blocks most of the active sites and masks the competition
with steam. Further, the maximum in the reaction rate can be
understood as follows. If we assume formate/carbonate is an
active intermediate during the reaction, then the rate of
decomposition of these species depend on the concentration
of steam in the feed [56]. At high concentration of CO, there
are not enough H2O molecules in the feed to accelerate the
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Fig. 9 e Normalized CO, CO2 and H2 concentrations in WGS reaction (a) Zr0.95Ru0.05O2Ld and (b) 5% Ru/ZrO2 (impregnated)
catalysts, respectively. The dotted line shows the equilibrium conversion.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 3 13969
decomposition. Therefore, this is the primary reason for the
decrease in the reaction rate at higher concentration of CO. On
the other hand, Fig. 11(b) shows a continuous increase in the
reaction rate with concentration of H2O without maximum in
the reaction rate. This shows that there are enough water
molecules in the feed, which facilitate the decomposition of
the formate/carbonate. This information was used to propose
the reaction mechanism over Zr0.95Ru0.05O2�d catalyst.
3.4. Kinetic model for WGS reaction
Numerous experimental and theoretical studies have been
performed to explore the reaction mechanism over various
catalysts. However, the exact nature of active intermediates is
still a matter of debate [2,15,28,57]. Most investigators agree
that the noble metal supported reducible metal oxide cata-
lysts are bi-functional with CO adsorption on noble metal and
H2O activation over the support [58]. In this regard, two
completely different mechanistic pathways namely, “redox”
or regenerative mechanism, and “associative” or adsorptive
mechanism have been proposed [2,9]. In redox mechanism,
CO adsorbs on the noble metal and reacts with the lattice
Fig. 10 e (a) Variation of fractional conversion of CO with W/FCOreaction.
oxygen of the support at metal-support interface to form CO2.
This results in the reduction of support with creation of oxide
vacancies, which would be rejuvenated by the oxygen pro-
vided by H2O, producing H2 [2]. The role of dispersed metallic
phase is not only restricted to the adsorption of CO but also
increases the reducibility of the support with the creation of
new active sites for activation of H2O [29].
On the other hand, the associativemechanism involves the
formation of surface carbon containing intermediate, e.g.
formate or carbonate from CO and OH which further de-
composes to H2 and CO2 [2,9]. The noble metals not only
facilitate the generation of the bridging OH group active sites
but also accelerate surface formate decomposition [59]. The
dissociative adsorption of H2O is the common step in both the
mechanisms [2]. The partial reduction of support increases
the rate of reaction for both the mechanisms [60]. For
example, in the formate mechanism, the reduced ceria sur-
face increases the concentration of bridging OH group active
sites. In the redox mechanism, reduced ceria (oxide vacancy)
is directly involved in the direct activation of H2O molecules
[54,61]. The stability of carbon containing intermediate de-
termines the reactionmechanism [57]. The nature of the oxide
(b) rate of reaction as function of temperature for WGS
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Table 2 e Reaction rates and activation energies for WGSreaction on various supported catalysts.
Catalyst Rate(mmol/g/s)
(�C)
Activationenergy(kJ/mol)
Reference
Au/Fe2O3 0.022(100) 52 [50]
Au/TiO2 0.3(100) 46 [50]
Pd/CeO2 5.6(180) 48 [51]
Ce0.78Ti0.2Pt0.02O2�d 7.54(280) 56.48 [52]
Ce0.98Pt0.02O2�d 4.5(220) 52 [52]
Ce0.65Fe0.33Pt0.02O2�d 4.05(275) 50.62 [53]
Au/CeO2 0.2(100) 34 [54]
Ti0.84Pt0.01Fe0.15O2�d 2.74(280) 63 [55]
Ti0.73Pd0.02Fe0.25O2�d 4.36(240) 42 [55]
Ce0.85Si0.1Ru0.05O2�d 1.64(220) 51 [24]
Ce0.85Fe0.1Ru0.05O2�d 1.4(220) 56 [24]
Zr0.95Ru0.05O2�d 3.51(220) 32 Present study
i n t e rn a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 313970
support has also a significant influence on the reaction
mechanism and the metal-support interface plays an impor-
tant role in governing the rate of decomposition of surface
carbon containing intermediate [62]. This originates from
either a direct or indirect involvement of the support [58]. For
example, noble metal supported CeO2 catalyst shows much
higher WGS activity in comparison with noble metal sup-
ported Al2O3 supported catalysts and this increase in the ac-
tivity is attributed to the reducibility and the oxygen storage
capacity of the ceria support [57]. Therefore, it is concluded
that the support directly participates in activating H2O mole-
cules. The support indirectly also influences the shape, size
and dispersion of the metal nanoparticles [63]. It also changes
the electronic state of metal nanoparticles and can stabilize
various ionic metal species [64].
Despite numerous experimental and theoretical studies,
the chemical nature of active carbon containing intermediate
and its true site location have not been clearly understood [2].
The initial transient rate of reaction of adsorbed formate with
water and adsorbed CO with water was quantified using a
novel SSITKA coupled with in situ DRIFTS and mass spec-
trometry experiments. It was observed that the formate is an
inactive or spectator species for the steady state WGS
Fig. 11 e (a) The effect of concentration of CO on the formation of
of H2O concentration on the formation of CO2 at a constant CCO
reaction [58,65]. The effects of reaction temperature and
support composition were also studied and it was found that
the reaction intermediates strongly depend on reaction
temperature, support composition, and Pt particle size
[2,65,66]. The reactivity of the intermediates formed during
the reaction was also investigated using in-situ DRIFTS/
SSITKA techniques. It was found that the rate of CO2 for-
mation is much higher than the rate of decomposition of
formats indicating that the observed formates are not the
active reaction intermediates [67].
It is important to note that the contribution of these
pathways to the overall rate of reaction is strongly dependent
on the experimental conditions [15]. However, the applica-
bility of the redox mechanism is restricted to the metal sup-
ported on “reducible” support. For non reducible supports
such as ZrO2, Al2O3 the utilization of lattice oxygen at low
temperature is unlikely during the reaction and it has been
reported in many studies that reaction mainly goes through
the formate mechanism [68]. It has been observed that the
WGS reaction precedes through a carboxylate (OCOH) inter-
mediate formed by direct oxidation of CO by hydroxyl groups
over Pt/Al2O3 catalyst [69]. In another study, two kinds of
formate namely active and inactive were identified over Pt/
Al2O3 [59,70]. The microkinetic modeling using DFT was
showed that the COOH mediated reaction pathway is
preferred over the redox pathway over Cu/ZrO2 catalyst and
the enhancement in electrostatic interaction between Cu ions
and adsorbates such as O and OH species was identified [71].
In another study, the observed differences in WGS activity
for different Cu supported ZrO2 polymorphs were explained
on the basis of different stability of the formate species on
these supports [72]. In-situ FTIR was used to investigate the
reactivity of mono and multi coordinated OH groups on Pt/
ZrO2 catalyst and it was found that mono coordinated OH
groups are active for formate formation while multi coordi-
nated OH groups and Pt are needed for formate decomposition
[73]. Therefore, based on the literature and our experimental
observations, a plausible reaction mechanism was proposed
to describe the reaction kinetics.
COþM! K1 COM (8)
CO2 at a constant CH2O [ 8.173 10L7 mol/cm3 and (b) effect
[ 11.2 3 10L7 mol/cm3, respectively for WGS reaction.
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Fig. 12 e The fitted rate of WGS reaction to kinetic model as function of concentration of (a) CO and (b) H2O.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n en e r g y 3 8 ( 2 0 1 3 ) 1 3 9 6 1e1 3 9 7 3 13971
H2OþM! K2H2OM (9)
H2OM þ S/k3OHS þHM (10)
COM þOHS/k4CO2 þHM (11)
HM þHM/k5H2 þ 2M (12)
M and S represent the vacant Ru metal and support site,
respectively. The adsorption of CO and H2O over Ru sites is
represented by Equation (8) and Equation (9), respectively. The
competitive adsorption of CO and H2O over the catalyst is
justified based on the fact that the rate of reaction shows a
maximum at higher concentration of CO. Therefore, it is ex-
pected that there is an optimum coverage of CO and H2O over
the catalyst surface. Equation (10) depicts the spillover of
adsorbed H2O species to the support with the formation of
hydroxyl groups. The formation of OH species over ZrO2 and
their participation in WGS reaction has been well reported in
the literature [73]. The formation of surface intermediate
HOCO from interaction between adsorbed CO molecule and
OH group and the subsequent decomposition with release of
CO2 and H2 is depicted by Equations (11) and (12). It has been
proposed that the decomposition of formate species is the rate
limiting step [56]. Therefore, while deriving rate expression, it
was explicitly assumed that decomposition of formate species
(Equation (11)) is the rate limiting step. Thus
rate ¼ K1234CCOCH2O�1þ K1CCO þ K2CH2O
�2 (13)
At constant concentration of H2O, the above equation can
be written as
�CCO
rate
�1=2
¼ DA1=2
þ BA1=2
� CCO ¼ Eþ F� CCO (14)
where, A ¼ K1234CH2O, B ¼ K1 and D ¼ ð1þ K2CH2OÞThe left side of Equation (14) with concentration of CO was
plotted and the values of E and F were determined from the
intercept and slope, respectively. A similar fit was also
obtained with the variation concentration of H2O and values
of K1, K2 and K34 were determined (see Fig. 12). The values for
K1 (cm3/mol), K2 (cm
3/mol) and K34 (mol/g s) are 3.32 � 105exp
(5733/RT), 6.52� 105exp (8796/RT) and 4.8� 106exp (�4153/RT),respectively.
4. Conclusions
Highly active and stable Zr0.95Ru0.05O2�d catalyst was devel-
oped for CH4 steam reforming and WGS reactions. The
detailed kinetics was studied for a wide range of experimental
conditions including effect of temperature, catalyst loading
and concentration of product/reactants concentration on the
reaction rates. The rates of reaction were first order in CH4
concentration and independent on concentrations of CO and
H2O. This indicates the adsorptive dissociation of CH4 is the
rate determining step. Further, the present catalyst was also
stable toward coke deposition even at much lower inlet steam
to carbon ratio. The high activity and selectivity (100%) toward
H2 production for WGS reaction is really promising. A lack of
CO methanation activity over present catalyst is also
encouraging in the context of development of Ru based cata-
lysts forWGS reaction and this is attributed to the ionic nature
of Ru species. Therefore, the present catalystmay be a suitable
alterative to noble metals (Rh, Pt, and Au) based catalysts for
the production of hydrogen.
Acknowledgments
Authors gratefully acknowledge the Gas Authority of India
Limited for financial assistance.
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