Insights on a methanation catalyst aging process: Aging characterization and kinetic study

Power to gas systems is one of the most interesting long-term energy storage solutions. As a result of the high exothermicity of the CO2 methanation reaction, the catalyst in the methanation subsystem is subjected to thermal stress. Therefore, the performance of a commercial Ni/Al2O3 catalyst was investigated over a series of 100 hour-long tests and in-process relevant conditions, i.e. 5 bar from 270 to 500 °C. Different characterization techniques were employed to determine the mechanism of the observed performance loss (N2 physisorption, XRD, TPO). The TPO analysis excluded carbon deposition as a possible cause of catalyst aging. The BET analysis evidenced a severe reduction in the total surface area for the catalyst samples tested at higher temperatures. Furthermore, a direct correlation was found between the catalyst activity decline and the drop of the catalyst specific surface. In order to correctly design a reliable methanation reactor, it is essential to have a kinetic model that includes also the aging kinetics. For this purpose, the second set of experiments was carried out, in order to determine the intrinsic kinetics of the catalyst. The kinetic parameters were identified by using nonlinear regression analysis. Finally, a power-law aging model was proposed to consider the performance loss in time.