Coal char gasification for co-production of fuel gas and methane decomposition catalysts

Partial gasification of coal char was conducted with addition of metal oxides for co-production of fuel gas and methane decomposition catalysts. Effect of the metal composition (Ni, Co and Fe based mono- or bi-metals) was investigated on the fuel gas production and the resultant catalyst surface and textural properties, morphology and performance in catalytic methane decomposition (CMD). Besides H₂-rich fuel gas production (the combustion energy up to 11.03–23.42 MJ/kg_char) from the gasification, the gasification residue can directly serve as the effective and efficient catalyst for CMD. The Fe and Fe–Co composite oxides were found to be better among the mono- and bi-metallic oxides for the fuel gas production during the gasification, respectively. The Ni-based mono-/bi-metallic catalysts could display high and stable methane conversion (up to 80%) during the 600-min CMD test at 850 °C. Promotional role of the second metal in CMD was discussed on the carbon diffusion, metal mobility and reducibility, formation and growth of the deposited carbons. The formed carbon morphology after CMD was analyzed based on the Kirkendall effect and Tammann temperature and further correlated to the potential catalyst deactivation.