Structural Changes of Ni and Ni-Pt Methane Steam Reforming Catalysts During Activation, Reaction, and Deactivation Under Dynamic Reaction Conditions

Ni-based catalysts are the most widely used materials to produce H-2 in large-scale methane steam reformers under stationary conditions. For domestic applications such as fuel cells, H-2 production involves the exposure of the catalysts to more dynamic conditions due to the daily startup and shutdown operation mode, making Ni-based catalysts susceptible to oxidation and deactivation. In this context, we report a systematic investigation of the structural changes occurring for monometallic Ni/MgAlOx and bimetallic NiPt/MgAlOx catalysts during methane steam reforming under transient conditions, comprising catalyst activation, operation, and deactivation processes. Besides extensive catalytic tests, the samples prepared by incipient wetness impregnation were characterized by complementary methods, including N-2-physisorption, X-ray diffraction, H-2-temperature-programmed reduction, and electron microscopy. Next, the structure of the Ni and Pt species was monitored under reaction conditions using time and spatially resolved in situ/operando X-ray absorption spectroscopy. The results obtained show that before catalyst activation by H-2-reduction, nickel diffuses into the support lattice and forms mixed oxides with magnesium. In the activated catalysts, Ni is present in the metallic state or alloyed with Pt. A clear beneficial effect of the noble metal addition was identified on both the activity and stability of the bimetallic NiPt/MgAlOx catalyst. In contrast, the pronounced oxidation and reincorporation of Ni into the support lattice were observed for the monometallic sample, and these catalyst deactivation effects are hindered in the bimetallic Ni-Pt catalyst. Overall, the outcome of our study not only helps in understanding the catalyst activation/deactivation processes at an atomic level but also provides the basis for the rational development of improved methane steam reforming catalysts.