Methane decomposition over Co thin layer supported catalysts to produce hydrogen for fuel cell

Co/Al2O3/Silica Cloth Thin Layer Catalysts (CoAS) for Catalytic Decomposition of Natural Gas (CDNG) were investigated using a new Multilayer Catalytic Reactor (MCR). The influence of Co loading and reaction temperature was evaluated. Irrespective of Co loading, initial CH4 conversion rises with TR, while for lifetime and carbon capacity (C/Ni, number of CH4 molecules decomposed for Ni atom until complete deactivation) it is not possible to find a direct relationship with other operating parameters or catalyst characteristics. However, Co loading significantly affects the catalytic activity: Co loading as high as 20 wt.% ensures both long lifetime and high H2 productivity. On the contrary of what occurs using Ni-based catalysts and irrespective of reaction temperature investigated, filamentous coke forms with a “base” reaction mechanism and Co catalyst can be regenerated in oxygen without any problem, thus allowing to realize a dual-step process for the production of “COx-free” hydrogen stream.