Very low Ru loadings boosting performance of Ni-based dual-function materials during the integrated CO2 capture and methanation process

Herein, the effect of the Ru:Ni bimetallic composition in dual-function materials (DFMs) for the integrated CO₂ capture and methanation process (ICCU-Methanation) is systematically evaluated and combined with a thorough material characterization, as well as a mechanistic (in-situ diffuse reflectance infrared fourier-transform spectroscopy (in-situ DRIFTS)) and computational (computational fluid dynamics (CFD) modelling) investigation, in order to improve the performance of Ni-based DFMs. The bimetallic DFMs are comprised of a main Ni active metallic phase (20 wt%) and are modified with low Ru loadings in the 0.1–1 wt% range (to keep the material cost low), supported on Na₂O/Al₂O₃. It is shown that the addition of even a very low Ru loading (0.1–0.2 wt%) can drastically improve the material reducibility, exposing a significantly higher amount of surface-active metallic sites, with Ru being highly dispersed over the support and the Ni phase, while also forming some small Ru particles. This manifests in a significant enhancement in the CH₄ yield and the CH₄ production kinetics during ICCU-Methanation (which mainly proceeds via formate intermediates), with 0.2 wt% Ru addition leading to the best results. This bimetallic DFM also shows high stability and a relatively good performance under an oxidizing CO₂ capture atmosphere. The formation rate of CH₄ during hydrogenation is then further validated via CFD modelling and the developed model is subsequently applied in the prediction of the effect of other parameters, including the inlet H₂ concentration, inlet flow rate, dual-function material weight, and reactor internal diameter.