Niuhu Zhouab,
Donglin Zhaoab,
Qin Suab,
Qiongguang Liab,
Weiwei Zhaab and
Shaojie Feng*ab
aKey Laboratory of Functional Molecule Design and Interface Process, Anhui Jianzhu University, Hefei, 230601, China. E-mail: fengshaojie@ahjzu.edu.cn
bAnhui Province International Center on Advanced Building Materials, Anhui Jianzhu University, Hefei, 230601, China
First published on 14th May 2024
Carbon-based catalysts catalyze methane decomposition to produce hydrogen is a very attractive technical route. Carbon black in carbon-based catalysts has the advantages of high catalytic activity, good stability and better tolerance to toxic impurities such as sulphur in the feedstock, which has become a hot topic of research for many scientists. In this work, the effect of heat treatment on the structural and surface properties of carbon blacks and their catalytic performance in hydrogen production from methane decomposition was investigated. A commercial carbon blacks N110 was selected to heat treatment with nitrogen or carbon dioxide atmosphere at 850 °C, respectively. The Raman spectrums indicated that the graphitization degree of modified carbon under two atmospheres were promoted with the treatment time increasing. BET results revealed that the specific surface area of the carbon black treated under carbon dioxide increased, while the specific surface area was unchanged for that of the carbon black treated under nitrogen. The catalytic test of the two modified carbon blacks for methane decomposition exhibited the almost same activity, which meant that the graphitization degree of carbon black is the key factor for methane decomposition rather than the specific surface area. It was suggested that highly graphitized carbon black could be used as the potential catalysts for hydrogen production from methane decomposition.
Currently, the main processes for hydrogen production are: steam methane (SMR)/dry reforming (DRM), catalytic methane decomposition (CMD), partial oxidation of methane (POM), water decomposition and coal/biomass gasification. Water decomposition processes driven by electricity or light to produce H2 are extremely interesting to study and there are no CO2 emissions during the production of H2.4 However, for light-driven water decomposition experiment, yields and costs are still extremely challenging for practical applications. SMR and DRM are the dominant hydrogen production processes today. Despite their maturity, these processes inevitably produce CO or CO2 by-products.5 Furthermore, complex and expensive separation processes are required to remove COx from the hydrogen stream. Hydrogen production from biomass gasification using various biomass sources (e.g., forest residues, wood waste, microalgae, crop residues and waste cooking oil) is also associated with large amounts of carbon dioxide, which has a significant impact on global warming. In contrast to these processes, CMD is a promising and environmentally friendly technology for hydrogen production. It is a heat-absorbing process with solid carbon and gaseous hydrogen as products. The reaction equation is as follows:
CH4(g) → C(s) + 2H2(g), ΔH = 75.6 kJ mol−1 |
Metal-based catalysts are commonly used for methane decomposition. The Fe,6–8 Co,9,10 Ni,11–13 Cu,14,15 etc. metal catalysts were reported to catalyze methane decomposition. Metal-based catalysts typically have high catalytic activity and low reaction temperatures. However, carbon deposits on the surface of metal catalysts, which cause the catalyst to deactivate, limited their application.
Carbon materials (activated carbon AC,16,17 CMK,18,19 coal char,20,21 carbon black,22–24 etc.) are also commonly used in the catalytic decomposition of methane to produce hydrogen. Carbon materials can accommodate more carbon deposition in the CMD process than metal catalysts, mainly due to their high specific surface area and abundant pore space. Carbon materials have better tolerance and conversion stability to sulfur and other toxic impurities in the feedstock, although they perform less well in CMD. The hydrogen production rate of carbon materials with different structures varies widely. It was reported that carbon black has the highest hydrogen production rate from methane decomposition of all carbon catalysts.4,25 However, it is not clear whether the structure or the surface area of the carbon material plays the key role in the catalytic decomposition of methane.
In this work, we aim to prepare modified carbon blacks with different structures by modulating the carbon black structure through heat treatment methods. The effect of heat treatment time on the structure and catalytic performance of the catalysts was investigated, and it was also explored whether the key factor affecting the catalytic performance was the graphitization degree or the specific surface area of the carbon black.
XCH4 = (FCH4;in − FCH4;out)/FCH4;in × 100% |
YH2;out = 2(FCH4;in − FCH4;out)/m |
Fig. 2 shows the specific surface area (Fig. 2a) and total pore volume (Fig. 2b) of N110, CB-N2-2 and CB-CO2-X (X = 1, 2, 3, 4); isotherms (Fig. 2c) and pore size distribution (Fig. 2d) of CB-CO2-4 (X = 1, 2, 3, 4). Fig. 2a clearly shows that the specific surface area of carbon black increased after high temperature treatment with carbon dioxide. Comparing with Fig. 2b, it is found that the results are almost the same as Fig. 2a, the pore volume of carbon black increases with the increase of carbon dioxide treatment time. Fig. 2c and d show the adsorption isotherm and pore size distribution of CB-CO2-4, respectively. In Fig. 2c, it was found that the CB-CO2-4 sample exhibited a type IV isotherm. For the type IV isotherm, hysteresis occurs in the desorption stage to the extent that capillary condensation occurs due to capillary condensation on the pores or irregular surfaces during the adsorption process. The average particle size of the CB-CO2-4 sample is 72 nm with a macroporous nature as can be observed in Fig. 2d. The main reason for the larger specific surface area of the CB-CO2-4 sample may be due to the redox reaction of carbon black in a carbon dioxide atmosphere, where carbon dioxide streams are flushed from the surface of the carbon black to form macropores.26
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Fig. 2 Specific surface area (a) and total pore volume (b) of N110, CB-N2-2 and CB-CO2-X (X = 1, 2, 3, 4); isotherms (c) and pore size distributions (d) of CB-CO2-4 (X = 1, 2, 3, 4). |
Fig. 3 shows the SEM images of N110 (a), CB-N2-2 (b) and CB-CO2-4 (c). As can be seen in Fig. 3a, the surface of N110 is relatively rough and well-defined, the particle size is about 30 nm, and the particles are adsorbed with each other to form large agglomerates. Fig. 3b shows that N110 was treated at high temperatures with a large range of sintering of the carbon particles and the formation of large pores. It is clear from Fig. 3c that the high temperature treatment in a carbon dioxide atmosphere makes the pores richer. At the same time, many pores appeared on the carbon surface in the presence of carbon dioxide gas flow. This is consistent with the BET results, which are mainly related to the oxidation reaction of the carbon material.
The XPS spectra of N110 and CB-CO2-4 are shown in Fig. 4. Fig. 4a shows the carbon spectrum on the N110 surface and Fig. 4b shows the carbon spectrum on the CB-CO2-4 surface. According to the C 1s precision spectral analysis, N110 consists of four main spectral peaks, and there are four positional binding energies on the surfaces of N110 and CB-CO2-4, 284.8 eV, 286.2 eV, 287.5 eV, and 289.9 eV, which correspond to the carbon compositions of C–C/C–H (adsorbed carbon), C–O, CO, and carbonate, respectively. N110 and CB-CO2-4 surfaces are dominated by sp3 C–C. The rest of the peaks represent the C–O, C
O and carbonate chemical states of the carbon materials, respectively. Comparison of the C 1s spectra of N110 and CB-CO2-4 shows that the C–O and C
O compositions are quite different. It may be due to reduction of C–O and C
O by redox reaction of surface oxides with C during high temperature treatment of N110.
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Fig. 5 Initial methane activity diagram (a) and the methane conversion rate per unit specific surface area (b). |
In recent years, it is controversial whether the specific surface area or the graphitization degree of carbon materials affects the catalytic performance of methane.20,25,27 The initial methane conversion and hydrogen production rates of all treated carbon materials (CB-N2-2 and CB-CO2-X) are significantly higher than those of N110, which indicates that the heat-treated carbon is more favorable for methane catalytic decomposition than that of N110. The specific surface area of the carbon material treated in the carbon dioxide atmosphere was much larger than that of the carbon material treated in the nitrogen atmosphere for the same treatment time, but the methane conversion was almost the same for both. Furthermore, the methane conversion over the modified carbon blacks was increased with the extension of heat treatment time under the same atmosphere environment (CO2) and different treatment time. The results suggest that the prolonging the heat treatment time of carbon materials is beneficial to the catalytic properties of carbon black, but the type of treatment atmosphere had no effect on the catalytic decomposition of methane. Therefore, we investigated the methane conversion per unit mole of carbon material to see if the specific surface area was a crucial factor in the catalytic performance of methane.
Fig. 5b shows the methane conversion per unit specific surface area of carbon materials. It clearly shows that the methane conversion per unit specific surface area decreases with increasing oxidation treatment time in a carbon dioxide atmosphere. Comparing Fig. 5b with Fig. 2a, it can be seen that the specific surface areas of N110 and CB-N2-2 are the same, while the methane conversion per unit specific surface area is different. The results indicate that the specific surface area of the carbon materials is not a factor affecting the catalytic performance of methane. This result contradicts the findings of Muradov et al.25
Fig. 6 shows the XRD spectra of N110 (a), CB-N2-2 (c), CB-CO2-4 (e) before catalysis and N110 (b), CB-N2-2 (d), CB-CO2-4 (f) after catalysis. Fig. 6 shows visually that the IC(101)/IC(002) ratios of catalysts (a), (c), and (e) are decreased compared to those of catalysts (b), (d), and (f), respectively. The result indicates that the carbon material catalysts are more ordered after catalysis than before catalysis, which means that the catalytic decomposition of methane is a process of ordered carbon deposition.
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Fig. 6 XRD of N110 (a), CB-N2-2 (c), CB-CO2-4 (e) and used N110 (b), used CB-N2-2 (d), used CB-CO2-4 (f). |
In order to have a more in-depth observation of the carbon deposits produced on the catalyst surface, SEM images of used N110 (Fig. 7a), used CB-N2-2 (Fig. 7b), and used CB-CO2-4 (Fig. 7c) were compared with Fig. 3. It was found that the catalyzed carbon grains intersected, grew and aggregated with each other. The produced carbon grew and deposited on the surface of the original carbon material.
The surface properties of the treated carbon black was investigated by Raman characterization. Fig. 9 shows the Raman spectra of the carbon materials. All the samples showed absorption peaks at 1345 cm−1 and 1595 cm−1, which correspond to the D and G peaks of carbon materials, respectively.29 The D peak is believed to be caused by structural defects in the graphite layer, while the G peak is caused by the expansion and contraction vibrations of the sp2 hybridized carbon atoms in the 2D hexagonal lattice. It is well known that the intensity ratio (ID:
IG) of the D and G peaks indicates the graphitization degree of carbon materials. This means that the smaller the ID
:
IG ratio, the higher the graphitization degree. Fig. 9a clearly shows that the ID/IG ratios of the treated carbon materials (b–f) are lower than those of N110, indicating that the heat treated carbon materials have a higher graphitization degree than N110. The ID/IG ratios of CB-N2-2 (b) and CB-CO2-2 (d) were found to be almost the same for commercial carbon black N110 treated at high temperature for the same time under N2 and CO2 atmospheres, respectively. However, it was found that the graphitization degree of the modified carbon materials (c, d, e and f) was increased with the increase of heat treatment time under the same atmosphere environment (CO2). The result indicates that the treatment time is the key factor in increasing the graphitization degree of carbon materials rather than the treatment atmosphere. This result agrees with the XRD results that the more graphitized of the carbon material correspond to the more order of structure.
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Fig. 9 Raman spectra of carbon materials before catalysis (a) and before and after comparative catalysis (b). |
Fig. 9b shows the Raman spectra of N110 (a), CB-N2-2 (c), CB-CO2-4 (e) before catalysis and N110 (b), CB-N2-2 (d), CB-CO2-4 (f) after catalysis. The ID:
IG ratios of the post-catalyzed carbon materials are all larger than that of the pre-catalyzed ones, and the D peak defects are also increased after catalysis. Combined with the catalytic performance graph (Fig. 5) and Raman spectra (Fig. 9), it was found that the catalytic performance increased as the graphitization degree increased. The catalytic results proved that the high graphitization carbon materials promoted the decomposition of methane. Comparison of the BET data and catalytic performance of two carbon materials (CB-N2-2 and CB-CO2-2) showed that the catalytic performance was almost constant for carbon materials with different specific surface areas, which suggests that the graphitization degree of the carbon materials plays a key role in methane decomposition rather than the specific surface area. The result is consistent with related reports that the active site for the decomposition of methane is located in the vicinity of the graphite edge.30
The higher ID/IG ratio of N110 than other catalysts may be related to the low methane conversion. In addition, the ID/IG ratio of CB-CO2-4 before catalysis is 0.622, which is lower than that of CB-N2-2 and N110. The result indicates that the defect density on the CB-CO2-4 surface is higher than that on N110 and CB-N2-2, or that many BAY clusters are distributed in the graphite edges of the CB-CO2-4 surface. The initial methane conversion of CB-N2-2 is almost the same as that of CB-CO2-2, even though the specific surface area of CB-N2-2 is lower than that of CB-CO2-2. The combination of XRD and Raman patterns showed that high temperature heat treatment can change the structure of carbon materials, increase the graphitization degree, increase the structural order of carbon black and at the same time increase the degree of graphite defects. The catalytic results confirm that the higher the graphitization degree and the more ordered the structure of the carbon black, the better the catalytic performance. The experimental results also showed that the graphitization degree of carbon materials is a key factor affecting the catalytic performance of methane.
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