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In this work, 3D particle-resolved CFD simulations have been performed to investigate the thermal effects of natural gas production from coke oven gas. The catalyst packing structures with uniform, gradient rise and gradient descent distribution and the operating conditions of pressure, wall temperature, inlet temperature and feed velocity are optimized for reduced hot spot temperature. The simulation results show that compared with packing structures with uniform distribution and gradient descent distribution, the gradient rise distribution could effectively reduce the hot spot temperature without affecting the reactor performance in the reactor with upflow reactants feeding, of which the reactor bed temperature rise is 37 K. Under the conditions with the pressure of 20 bar, wall temperature of 500 K, inlet temperature of 593 K, inlet flow rate of 0.04 m/s, the packing structure with gradient rise distribution exhibits the minimum reactor bed temperature rise of 19 K. By optimizing the catalyst distribution and operation conditions, the hot spot temperature of CO methanation process could be dramatically reduced by 49 K at the sacrifice of slightly reduced CO conversion.

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In this study, a series of NiO-CeO2 mixed-oxide catalysts have been prepared by a modified co-precipitation method similar to the one used for the synthesis of hydrotalcites. The syntheses were carried out at different pH values (8, 9 and 10), in order to determine the influence of this synthetic variable on the properties of the obtained materials. These materials were characterized by using different techniques, such as TGA, XRD, ICP, N2 adsorption-desorption isotherms, H2 temperature-programmed reduction (H2-TPR), and electron microscopy, including high-angle annular dark-field transmission electron microscopy (HAADF-TEM) and EDS. The characterization results revealed the influence of the preparation method, in general, and of the pH value, in particular, on the textural properties of the oxides, as well as on the dispersion of the Ni species. The catalyst prepared at a higher pH value (pH = 10) was the one that exhibited better behavior in the CO methanation reaction (almost 100% CO conversion at 235 °C), which is attributed to the achievement, under these synthetic conditions, of a combination of properties (metal dispersion, specific surface area, porosity) more suitable for the reaction.

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Efficient conversion of CO-rich gas to methane (CH4) provides an effective energy solution by taking advantage of existing natural gas infrastructures. However, traditional chemical and biological conversions face different challenges. Herein, an innovative biophotoelectrochemistry (BPEC) system using Methanosarcina barkeri-CdS as a biohybrid catalyst was successfully employed for CO methanation. Compared with CO2-fed BPEC, BPEC-CO significantly extended the CH4 producing time by 1.7-fold and exhibited a higher CH4 yield by 9.5-fold under light irradiation. This superior conversion of CO resulted from the fact that CO could serve as an effective quencher of reactive species along with the photoelectron production. In addition, CO was used as a carbon source either directly or indirectly via the produced CO2 for M. barkeri. Such a process improved the redox activities of membrane-bound proteins for BPEC methanogenesis. These results were consistent with the transcriptomic analyses, in which the genes for the putative CO oxidation and CO2 reduction pathways in M. barkeri were highly expressed, while the gene expression for reactive oxygen species detoxification remained relatively stable under light irradiation. This study has provided the first proof-of-concept evidence for sustainable CO methanation under a mild condition in the self-replicating BPEC system.

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CO methanation from electrochemical CO reduction reaction (CORR) is significant for sustainable environment and energy, but electrocatalysts with excellent selectivity and activity are still lacking. Selectivity is sensitive to the structure of active sites, and activity can be tailored by work function. Moreover, intrinsic active sites usually possess relatively high concentration compared to artificial ones. Here, antisite defects MoS2 and WS2 , intrinsic atomic defects of MoS2 and WS2 with a transition metal atom substituting a S2 column, were investigated for CORR by density functional theory calculations. The steric hindrance from the special bowl structure of MoS2 and WS2 ensured good selectivity towards CO methanation. Coordination environment variation of the active sites, the under-coordinated Mo or W atoms, effectively lowered the work function, making MoS2 and WS2 highly active for CO methanation with the required potential of -0.47 and -0.49 V vs. reversible hydrogen electrode, respectively. Moreover, high concentration of active sites and minimal structural deformation during the catalytic process of MoS2 and WS2 enhanced their attraction for future commercial application.

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Nickel (Ni) catalysts supported on mesoporous graphitic carbon nitride (mpg-C3N4) were synthesized through simple impregnation method with air and nitrogen calcination atmosphere for CO methanation. The effects of pretreatment gas on catalyst structure, surface characteristics, and Ni species reducibility were investigated. Under air-calcination condition, the increase in specific surface area of the catalyst can be ascribed to the creation of mesopores and exfoliation of bulk mpg-C3N4 to form thin sheets. However, excessive Ni content on the catalyst accelerated the decomposition of the mpg-C3N4 support during calcination. The catalysts calcined in nitrogen showed lower surface area and fewer number of pores compared to air-treatment. The Ni/mpg-C3N4 catalyst calcined in air with Ni loading 10% exhibited enhanced medium-temperature activity for CO methanation with 79.7% CO conversion and 73.9% CH4 selectivity. This finding can be explained by the formation of mpg-C3N4 thin sheets, which increased the number of catalyst active sites. The CO methanation performance of Ni/mpg-C3N4 catalysts calcined in air was superior to those calcined in nitrogen. Interestingly, CO2 formed by water-gas shift reaction at 320 °C also contributed to the overall methane formation through CO2 methanation. Therefore, mpg-C3N4 thin sheets can be an interesting support for nickel catalyst for COx methanation.

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Ru/TiO2 catalysts exhibit an exceptionally high activity in the selective methanation of CO in CO2 - and H2 -rich reformates, but suffer from continuous deactivation during reaction. This limitation can be overcome through the fabrication of highly active and non-deactivating Ru/TiO2 catalysts by engineering the morphology of the TiO2 support. Using anatase TiO2 nanocrystals with mainly {001}, {100}, or {101} facets exposed, we show that after an initial activation period Ru/TiO2 -{100} and Ru/TiO2 -{101} are very stable, while Ru/TiO2 -{001} deactivates continuously. Employing different operando/in situ spectroscopies and ex situ characterizations, we show that differences in the catalytic stability are related to differences in the metal-support interactions (MSIs). The stronger MSIs on the defect-rich TiO2 -{100} and TiO2 -{101} supports stabilize flat Ru nanoparticles, while on TiO2 -{001} hemispherical particles develop. The former MSIs also lead to electronic modifications of Ru surface atoms, reflected by the stronger bonding of adsorbed CO on those catalysts than on Ru/TiO2 -{001}.

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Gas-phase ruthenium clusters Ru(n)(+) (n=2-6) are employed as model systems to discover the origin of the outstanding performance of supported sub-nanometer ruthenium particles in the catalytic CO methanation reaction with relevance to the hydrogen feed-gas purification for advanced fuel-cell applications. Using ion-trap mass spectrometry in conjunction with first-principles density functional theory calculations three fundamental properties of these clusters are identified which determine the selectivity and catalytic activity: high reactivity toward CO in contrast to inertness in the reaction with CO2; promotion of cooperatively enhanced H2 coadsorption and dissociation on pre-formed ruthenium carbonyl clusters, that is, no CO poisoning occurs; and the presence of Ru-atom sites with a low number of metal-metal bonds, which are particularly active for H2 coadsorption and activation. Furthermore, comprehensive theoretical investigations provide mechanistic insight into the CO methanation reaction and discover a reaction route involving the formation of a formyl-type intermediate.