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Volume 117
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Laboratory-scale demonstration of the high-potential applicability of porous α-Al2O3-supported Ni catalyst in fluidized-bed methane reforming
Yizheng Li a b c, Na Xu a, Yixin Huang a, Hongxu Zhang d, Ke Li d *, Zhanguo Zhang a b *, Guangwen Xu a *
a Key Laboratory on Resources Chemicals and Material of Ministry of Education, Shenyang University of Chemical Technology, Shenyang, 110142, China
b School of Materials Science and Engineering, Shenyang University of Technology, Shenyang, 110870, China
c School of Environmental and Chemical Engineering, Shenyang University of Technology, Shenyang, 110870, China
d Binzhou Huanghai Science and Technology Research Institute Co., Ltd., Binzhou, 256601, China
10.1016/j.partic.2026.07.013
Volume 117, October 2026, Pages 275-286
Received 7 May 2026, Revised 3 July 2026, Accepted 18 July 2026, Available online 25 July 2026, Version of Record 6 August 2026.
E-mail: like@qiaochang.com; zhangaist@syuct.edu.cn; gwxu@syuct.edu.cn
Highlights

• A robust porous α-Al2O3 supported Ni catalyst was developed for CH4 reforming.

• Lab-scale catalytic fluidized-bed reforming tests were done at severe conditions.

• Stable and near-equilibrium CH4 conversion was obtained over a 137 h test period.

• The catalyst gave a coking rate of 0.009 wt%/h and an attrition rate of 0.063 wt%.

• The catalyst proved high potential applicability in the fluidized bed reforming.


Abstract

Industrial application of the fluidized bed methane reforming technology for syngas production requires a robust catalyst with simultaneously high activity, high anti-coking ability and high attrition resistance. A highly fluidizable porous α-Al2O3 supported Ni catalyst was tested in a 50 mm I.D. fluidized-bed reactor system for the methane reforming. After the minimum catalyst charge needed for attaining the near-equilibrium CH4 conversion was determined through a set of 340 min dry reforming tests, a 137 h continuous CO2/water-steam combined bi-reforming test was conducted in a stream composed of a mass flow of 3 L/min CH4, 1 L/min CO2 and 2 L/min H2O(g) at 0.2 MPa, 810 °C and a space velocity of 18 L/(g h) to confirm the catalyst's activity stability. Near-equilibrium CH4 conversions and slightly higher than equilibrium H2/CO ratios were obtained over most of the test period. Quantification of the spent bed particles and the fines entrained into a downstream filter was conducted to estimate the average attrition rate of the catalyst and a low rate of 0.063 wt%/h was obtained. TG measurement of the spent catalyst was performed to evaluate the average carbon deposition rate, and a small rate of 0.009 wt%/h was obtained. All these together demonstrate that the tested catalyst has high-potential applicability in the fluidized bed methane reforming process.

Graphical abstract
Keywords
Fluidized-bed reactor; Methane bi-reforming; Ni-based catalyst; Porous α-Al2O3 support
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