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

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 degrees 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.