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Abstract: A 1% Fe-30% Hf over yttria-stabilized zirconia catalyst in cornbination with novel plasma-assisted activation
techniques for a direct partial oxidation of methane to methanol was tested using dielectric barrier discharge plasma at am-
bient temperature and atmospheric pressure. However, instead of methanol, the reaction products were dominated by H2,
CO, COZ , C2, and H20. A catalytically activated plasma process increased the production of methanol compared with a
noncatalytic plasma process. The maximum selectivity of methanol production was achieved using a catalyst that was treat-
ed at higher applied power.
Key words : methane oxidation ; dielectric barrier discharge ; catalyst ; plasma activation ; rare earths
CLC number: Document code: A Article ID: 1002 - 0721(2006)05 - 0513 - 05
The catalytic conversion of methane to methanol the maximum yield of methanol obtained thus far p i n g
is one of the major challenges faced by chemists. OCR! on any catalyst is less than 25%, whereas meth-
Methane, as the major constituent of natural gas, is anol selectivity is higher than 5 0 % , which is far below
the cheapest source of hydrocarbons, and the demand the requirement for making OCM economically attrac-
for methanol is expected to increase in the near future. -
tive ( > 30% 40%)[41.
Currently, methanol is produced using synthesis gas The oxidation of methane to methanol in nonther-
(CO, C 0 2 , and H2) . However, this process can be mal plasmas has been investigated worldwide using co-
drastically changed if an effective method to oxidize rona discharges, spark discharges, gliding arc, and
methane to methanol is found. Catalytic homogeneous dielectric barrier discharge (DBD) at atmospheric pre-
oxidation of methane at low temperatures is economi- ssure and ambient temperature. As a part of the inves-
cally interesting but very difficult to achieve because of tigation process, some researchers tried to add auxilia-
the high stability of C - H bonds. Much work was re- ry gases, such as hydrogenr5], airr5-'] , oxygen'6-91,
ported in the past decade on catalytically oxidative noble gas'7' l o ] . Others used different types of plasma
coupling of methane (OCM) , a promising process for discharges that possibly led to the distribution of dif-
the direct conversion of natural gas into ferent products"' - 12' .
Due to the high degree of oxidation reactions in the This research is a comprehensive study of the
gaseous phase as well as on the surface of the catalyst, performance of the plasma process and 1%Fe-30% Hf
Copyright @ZOOS, by Editorial Committee of Journal of the Chinese Rare Earths Society, Published by Elsevier B. V . All rights reserved.
514 JOURNAL OF RARE EARTHS, Vol. 24, No.5 , Oct 2006 .
over yttria-stabilized zirconia (YSZ) catalyst for partial constant in the range of 8 . 5 - 9.5 pF in an air-filled
oxidation of methane. DBD was chosen as the plasma gap condition.
medium due to the mild temperature condition that
probably improves methanol synthesis. Among all the
1.2 Power supply
metal catalysts, well-dispersed Fe was believed to be Plasma was generated by AC power supply (Auto
the most active species that has the ability to activate electric, model A1831), which has a maximum volt-
methane molecules on the catalyst ~ u r f a c e " ~ - ' The
~~. age and frequency of 10 kV and 20 kHz , respectively.
reaction that occurs on the catalyst surface is the key A digital power meter (Metex, model M-3860M) was
for the conversion of methane to methanol. YSZ was inserted into the electric line of power supply to mea-
used as the catalyst support. In methanol synthesis, sure the total power supplied to the reactor. The typi-
YSZ is claimed to be an active component. YSZ cal waveform of the voltage and the current used dur-
showed better performance as the catalyst support for ing the experiments is shown in Fig. 2.
methane reforming compared with A1203and Si0,'151.
1.3 Materials
The existence of Hf in the catalyst structure was used
to maintain the conductivity of catalyst due to molecule All experiments were carried out by introducing
structure. Conductivity is one of the main factors that methane (CH4, purity > 99.99% ) and oxygen ( 02,
can affect the oxidation rate of a reaction. purity > 99.9% ) with fixed methaneoxygen ratio of
4: 1 (volume basis). The input gases were controlled
1 Experimental by calibrated mass flow conbllers (Milipore, model
Fig. 1 shows the experimental setup. Methane and FC-280SAV). Analysis of the products was carried out
oxygen were introduced into the reactor at room temper- using gas chromatography ( YoungLin , model M600D )
ature and atmospheric pressure. The products were an- with a thermal conductivity detector (TCD , Column:
alyzed by gas Chromatography. Details of each part of Hayesep D 80/100) for measuring Hz and CH4, and a
the system are described in the following sections. flameionized detector (FID) for measuring CH4 and
higher hydrocarbons.
1.1 Reactor
The evaluation of system performance was done
The reactor is a cylindrical Pyrex tube (ID of 7.5 on the basis of product selectivity and methane conver-
mm) with two parallel straight wires ( 0 . 2 mm diame- sion that are formulated as:
ter, stainless steel) as the inner metal electrode and moles of Hz produced
x 100%
silver film coated on the outer side of the tube as the Of H2 = 2 x moles of CH4 converted
outer electrode. A high-frequency alternating current
(AC) power supply was connected to the electrodes. x x moles of C,H, produced X
The effective volume and length of the reactor were Selectivity of C,H, =
moles of CH4 converted
8.8 ml and 200 mm, respectively. To maintain the 100% (2)
similarity of the reactor configuration, e. g. , electro- moles of CH30H produced
Selectivity of CH@H = moles of cH, converted X
des gap distance, the reactor capacitance was checked
by an RCL meter (Fluke PM6304) before and after 100% (3)
the experiments. The reactor capacitance was kept
I
AC power supply
I
Blow heater
Catalyst
moles of CO, produced the YSZ catalyst. Using XRD analysis, the content of
Selectivity of CO, = x 100%
moles of CH, converted Fe , which was only 1% by mass weight, was relative-
ly difficult to detect.
moles of CH, conversion
Conversion of CH4 =
moles of initial CH4
x 100% 1.4 Catalyst treatment
(5) Novel catalyst activation approaches by plasma
The catalyst was prepared by sol-gel technique were used as the variables for the investigation. It be-
using nitrate solution of metal precursors dissolved in gan with the inert gas-plasma treatment. In our experi-
ethanol and oxalic acid, which act as the precipitating ment, first, helium was used at applied power of 75 W
agents. The nitrate solution consisted of 8% mol frac- for 2 h . The flow of helium was controlled at
tion of Yz03and 1% mol fraction of Fe in the solid so- 10 ml*min-'. The next step was plasma-assisted oxi-
lution of 30% rnol fraction of Hf02 and 61% mol frac- dation (PAO) , which was carried out by flowing a gas
tion of ZrO,. The gel was formed by quick mixing of mixture of oxygen-helium at the ratio of 6 : 4 for 2 h .
nitrate and oxalic acid solution. To ensure equal spe- The total gas flow rate and supplied power were 10
cies distribution on the gel, the stirring was vigorous ml-min-' and 50 W, respectively. The third step was
during the phase transformation from liquid to gel. The plasma-assisted reduction (PAR) , which was done by
gel thus produced was heated to evaporate the solvent flowing a gas mixture of hydrogen-helium in the ratio
and dried at atmospheric air. Calcination was done by of 6 : 4. Plasma reduction was done at the supplied
increasing the oven temperature at the rate of 2 . 5 power of 50 W and total gas flow rate of 10 ml-min-'
T a m i n - ' from room temperature to 650 C
' and kept for 2 h . Fig. 4 shows the waveform of applied plasma
constant for 8 h . Fig. 3 shows the XRD spectrum of during the activation process. To check the effects of
the catalyst, which confirms the stable cubic structure each step, the treatments using the catalyst was divid-
of YSZ. It also shows that the addition of 30% Hf ed into four cases as follows: ( 1) no-treatment, ( 2 )
(Fig.3(b)) does not change the crystal structure of helium plasma treatment, ( 3 ) helium + PA0 treat-
"t f LUU
ment, and ( 4 ) helium + PA0 + PAR treatment. To
check the stability and durability of the catalyst, con-
tinuous reaction was canied out for 80 min and the
first data point was obtained at the 20th minute.
<
._2
2
*
z
3
1-200 -2
-25 -15 -5 5 15 25 2) lie : 02=4 : 6, so w
'Time cycld !-Is (3) H e : H,-4 : 6, SOW
-6
Fig.2 Voltage and current profile -2 -1 0 I 2
Timc/lOTmin
(3) Hc : H2=4 : 6, 5 0 W
I -0.08
10 20 30 40 50 60 70 80 00
-2 -1 0 1 2
2 "/(") Timeil0-' inin
Fig.3 XRD spectra of catalyst after calcination Fig.4 Profile of voltage ( a ) and current waveform ( b ) of plas-
( 1 ) Pure YSZ; (2) 30% Hf/YSZ ma-assisted catalyst activation
516 JOURNALOFRAREEARTHS, Vo1.24, No.5, Oct. 2006
Table 1 Methane conversion and products distribution (data were obtained at the ratio of CH,:O2= 4: 1 and flow
rate of 30 ml*mh-’)
Table 2 CH,:O, = 4:1, Effects of catalysts on methane conversion and products distribution (Data were obtained at
ratio of flow rate of 30 ml-min-' and suDDlied Dower of 80 W)
Selectivity/% Yields/%
Supplied CHq
treatment conversion1% Hz co co2 ~
cz _
c3
_
CH30H
Blank 25.76k3.56 14.19k2.38 48.44k3.07 21.4722.63 15.33k2.04 5.14t1.22 4.49k0.57
YSZ 30.80k4.17 28.46k2.18 39.01 k3.079 30.48*2.74 14.90k1.54 0.00 * 0 6.64 f 0.31
No-treatment 24.25+4.34 17.03k2.13 45.54k4.57 20.78k2.67 15.32 k 2.14 3.26k1.23 4.89k0.44
He 34.91k3.33 20.09k2.29 45.02k1.73 11.84k1.37 14.47*1.58 0.00*0 10.14k0.8
He + PA0 30.84 k 2.36 23.72k2.29 54.41 f 2.25 32.05 k 1.78 9.45 f 2.29 o.oo*o 7.42 f 0.22
He + PA0 + FAR 35.34 f 2.56 20.13k1.98 46.77k1.13 11.98k1.29 15.57k1.96 0.00 k 0 9.63 k0.25
Without any treatment, the catalyst does not show activation the production of H, will
any significant activity in terms of the products distri- decrease as some methane molecules will be adsorbed
bution differences compared with the blank or pure and reacted with attached 0, to form methanol. This
plasma process. The production of methanol was also occurred in case of CO and CO, . However, a dif-
around 4 . 5 % . To study the effect of pure YSZ on the ferent result was found when the catalyst was oxidized
plasma process, commercialized YSZ made by by 0,.The conversion of CO and especially that of
TOSOH , was placed in the reactor. It showed that the CO, became higher, which reduced the formation of
yield of methanol increased by factor of 1.4. Another
methanol. Oxidation of the catalyst transforms the met-
interesting finding in the experiments was the oxidation
al into metal-oxide catalyst, or weak bonding of metal
of CO into CO,. The concentration of COz drastically
and oxygen occurs on the surface of the catalyst. Met-
increased from 21% to 30% and was simultaneously
al-phase transformation decreases the activity to adsorb
followed by a decrease in the concentration of CO in
methane ; the most possible mechanism that results in
the products. YSZ has oxygen vacancy sites that ad-
this reduced activity is attributed to the formation of
sorb 0 - onto the surface of the catalyst, based on this
CO and CO,. This condition can be overcome by con-
kinetic scheme"91 :
ducting the reduction process on the catalyst. Table 2
O2 + e-0, - (12)
shows that the production of methanol of the PAR case
0,- + 2e-O;- (13)
was 2 % higher than that without-PAR treatment case.
0 2 2 - + 2 0 - (dissociation) (14)
Based on the amount of methanol produced, the PAR
0- + Vo,s+ e + O,,,,(incorporation) (15)
and PA0 are not urgently required to boost the pro-
The Kroger-Vink notation is used for lattice de- duction of methanol. Helium plasma (or probably oth-
fects : denotes an oxygen vacancy on the surface of
er inert gases) treatment was particularly adequate to
the catalyst; O,,,, , an oxygen ion in the lattice form; activate the catalyst.
and e , an electron. Using this proposed formulation,
YSZ is classified as a material for selective oxidation 3 Conclusion
in the thermal process. This role was not changed in The partial oxidation of methane using a DBD in
the plasma reaction caused by the dense population of the presence of 1 % Fe-30% Hf over YSZ was dis-
0 ions and electrons. However, only the surface-lat- cussed. The maximum methane conversion of the non-
tice oxygen will be accessible for the catalytic reac- catalytic process is 2 5 . 7 % at a flow rate of
tion. The reaction between methanelC0 and surface- 30 ml-min-' and a supplied power of 80 W. The
lattice oxygen can be the reason for the increasing
products are dominated by Hz, CO, CO,, and C,.
methanol and C 0 2 concentrations.
The plasma activation techniques show that the catalyst
By treating the catalyst using helium, the metha-
can be activated, and the yield is different using dif-
nol yield increased from 5% to 10%. It can be prop-
ferent plasma treatment methods. Activated by inert
osed that the Fe sites that activate methane on the cat-
gas (helium), the catalyst shows the highest produc-
alyst surface can be also activated by helium plasma
tion of methanol. However, PA0 transforms the reac-
exposure. Panov et al . described methane activation
tants to complete oxidation products by producing more
on so-called a-oxygen sites that are formed on Fe
CO and CO,.
sites"31. Knops-Gerrits and Goddard showed the evi-
dent activation of Fe when the Fe metal concentration Acknowledgments: The authors are thankful to the Korea In-
was > 0. 5%[201. Based on the methane and oxygen stitute of Science and Technology for its support.
518 JOURNAL OF RARE EARTHS, Vol, 24, No.5 , a t . 2006
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