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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Tuning Methanol Transformation Pathways for Sustainable Steam Reforming: Na-Promotion Effects on Ag/m-ZrO 2 Catalysts

This work investigates the influence of sodium promotion on Ag/m-ZrO 2 catalysts for methanol steam reforming (MSR), focusing on activity, selectivity, surface chemistry, and mechanistic pathways. Temperature programmed reduction (TPR), XANES/EXAFS, CO 2 TPD, DRIFTS, and temperature programmed surface reaction methods were combined with fixed bed MSR testing to develop an integrated structure–function understanding of Na-modified Ag-ZrO 2 interfaces. Na addition systematically increases surface basicity, stabilizes strongly basic O 2− sites, and weakens the ν(CH) vibrational mode of surface formate, thereby facilitating C–H bond scission and accelerating decarboxylation to CO 2 . At moderate promoter levels (0.5–1.0 wt.% Na), the catalysts show significantly enhanced CO 2 selectivity and increased conversion relative to unpromoted Ag/m-ZrO 2 , while CH 4 formation remains negligible. Excessive Na (≥1.8 wt.%) leads to slower formate decomposition, greater carbonate stabilization, and suppressed conversion, revealing a narrow optimum around 1 wt.% Na. Short-term stability testing demonstrates steady conversion and product selectivity for both unpromoted and Na-promoted catalysts, with the latter maintaining markedly higher CO 2 selectivity. Although Pt/YSZ retains far superior intrinsic activity at ~10× higher space velocity, Ag offers a cost-advantaged alternative where lower cost metals are desirable. Collectively, these findings show that Na promotion enables tunable MSR selectivity on Ag/m-ZrO 2 by directing formate decomposition toward the CO 2 -forming pathway.

CO2 selectivity↗
DOE OSTI2026

Suppressing CO formation in low-temperature methanol steam reforming via Ce-modified CuZnGa layered oxide catalysts

Cu-based layered double hydroxides (LDHs) are widely recognized as effective catalysts for low-temperature methanol steam reforming, yet achieving high hydrogen productivity together with near-complete suppression of CO formation remains challenging. Here, we report the synthesis and evaluation of a series of CuZnGa LDH-derived catalysts and Ce-modified analogues prepared via an aqueous miscible organic method, which enables high metal dispersion and precise structural control. The optimized CuZnGa catalyst exhibits a hydrogen production rate of 16.9 µmol H 2 ·g cat −1 ·s −1 at 180 °C with an H 2 /CO ratio exceeding 3500, outperforming many state-of-the-art low-temperature systems. Importantly, the incorporation of small amounts of Ce further suppresses CO formation while maintaining high hydrogen productivity. Combined spectroscopic characterization and density functional theory calculations reveal that Ce is incorporated into the LDH lattice by substituting Ga 3+ sites up to a critical threshold, beyond which highly dispersed CeO x species are formed. These species provide mobile lattice oxygen that participates in a Mars-van Krevelen-type pathway, selectively oxidizing CO and suppressing the reverse water-gas shift reaction. This study establishes a clear relationship between Ce speciation, oxygen mobility, and catalytic selectivity in LDH-derived systems. The resulting catalysts demonstrate the potential of interface-engineered Cu-based materials for efficient low-temperature hydrogen production with minimal CO contamination.

09 BIOMASS FUELS↗
DOE OSTI2026

Methanol Steam Reforming on Ru/m-ZrO 2 : Sodium Promotion of the CO 2 -Forming Pathway

Sodium (Na) promotion of Ru/m-ZrO 2 was investigated to elucidate how an alkali modification tunes selectivity in methanol steam reforming (MSR). H 2 -TPR/XANES/EXAFS show that Na increases surface basicity and strengthens Ru–O interactions, shifting RuO x reduction and H 2 spillover to a higher temperature. DRIFTS reveals Na-induced red shifts of the formate ν(CH) band and changes in OCO vibrational splitting, consistent with weakening of the formate C–H bond and an altered binding geometry. CO 2 -TPD confirms a monotonic shift toward stronger basic sites with increasing Na concentrations. Under MSR conditions, Na selectively increases CO2 concentration at the expense of CO. At ~80% conversion and 325 °C, CO 2 selectivity increases from 12.0% (unpromoted) to 16.2, 21.0, and 26.5% for 0.5, 1.0, and 1.8% Na, respectively; at ~300 °C and ~66–69% conversion, CO 2 selectivity increases from 8.6% to 23.7% at 1.8% Na. Transient MSR experiments further show earlier and larger H 2 evolution upon Na addition, corroborating the promotion of the dehydrogenation/decarbonylation route to CO 2 + H 2 . We propose that Na increases basicity and modifies the Ru–support interface to favor formate dehydrogenation/decarboxylation, thereby increasing the H 2 yield and lowering CO formation. Ru’s higher-energy, less occupied d-band stabilizes CO and oxygenated intermediates more strongly in the reforming environment, making the CO-forming pathway more resistant to suppression than on Pt.

CO2 selectivity↗
DOE OSTI2023

Isotope effect in formaldehyde steam reforming on Pt/m-ZrO 2 : Insight into chemical promotion by alkalis

Infrared spectroscopy, temperature programmed reaction mass spectrometry (TP-reaction/MS), and catalyst testing were used to investigate alkali promotion of dehydrogenation selectivity during formaldehyde steam reforming (FSR) on Pt/m-ZrO 2 . In a preferred pathway, formaldehyde reacts with water forming hydrogen and formate, followed by forward formate decomposition to CO 2 and H 2 . Alkali-doping of 2 wt% Pt/m-ZrO 2 increases catalyst basicity, which weakens the formate C-H bond promoting formate dehydrogenation / decarboxylation. Promotion by alkali in FSR was observed through a formate nu(CH) band shift to lower wavenumbers in infrared spectroscopy, and through a decrease in the normal isotope effect in switching from H-to D-labeled formalde-hyde in TP-reaction/MS.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Simulation of 12-bed vacuum pressure-swing adsorption for hydrogen separation from methanol-steam reforming off-gas

This study focuses on analysis of a 12-bed vacuum pressure-swing adsorption (VPSA) process capable of purifying hydrogen from a ternary mixture (H 2 /CO 2 /CO 75/24/1 mol%) derived from methanol-steam reforming. The process produces 9 kmol H 2 /h with less than 2 ppm and 0.2 ppm of CO2 and CO, respectively, to supply a polymer electrolyte membrane fuel cell. The process model is developed in Aspen Adsorption® using the “uni-bed” approach. A parametric study of H 2 purity and recovery with respect to adsorption pressure, adsorbent height, activated carbon:zeolite ratio, feed composition, and number of beds is performed. Results show 12-bed VPSA can meet the H 2 purity goals, with H 2 recovery as high as 75.75%. Adsorption occurs at 7 bar, the column height is 1.2 m, and the adsorbent ratio is 70%:30%. Furthermore, a 4-bed VPSA can achieve the same purity goals as the 12-bed process, but H 2 recovery decreases to 61.34%.

03 NATURAL GAS↗
DOE OSTI2022

CH 4 steam reforming on Pt + Pd/Al 2 O 3 monolith: impact of Mn 0.5 Fe 2.5 O 4 spinel addition

The performance of Pt + Pd/Al 2 O 3 monolith catalysts was analyzed under a feed (H 2 + CO + CH 4 + NO + O 2 + H 2 O + CO 2 ) simulating the exhaust gas of stoichiometric natural gas vehicles (NGVs). The flow reactor results show enhanced low temperature (<400 °C) CH 4 oxidation activity under cyclic lean/rich feed modulation and with Mn 0.5 Fe 2.5 O 4 (MFO) spinel addition to the platinum group metal (PGM) catalyst. In the absence of the MFO spinel, the PGM catalyst can achieve full CH 4 conversion, but the presence of spinel in the catalyst limits the high temperature (>500 °C) CH 4 conversion. The depletion of gas phase O 2 , as indicated by the detection of products CO and H 2 in the reactor effluent at higher temperature and CH 4 conversion, portends the emergence of steam reforming of CH 4 (SRM). To investigate the cause of the detrimental impact of spinel under the high temperature, net rich regime, we show through a combination of SRM experiments and post-reaction catalyst characterization that SRM is negatively impacted by the accumulation of Mn and Fe spinel species on the PGM catalyst. This is due to the migration of the base metal species and potential encapsulation and blockage of PGM active sites. The latter is supported by density functional theory (DFT) calculations that indicate favorable metal oxide decoration of active Pt step sites. Lastly, a zoned catalyst design is developed that mitigates the detrimental metals migration while exploiting the methane conversion enhancement afforded by spinel oxides under oxygen rich conditions.

03 NATURAL GAS↗
DOE OSTI2020

Mechanistic insights into the catalytic methanol steam reforming performance of Cu/ZrO 2 catalysts by in situ and operando studies

Here, we assessed the catalytic properties of the Cu/ZrO 2 interface in methanol and formaldehyde steam reforming (MSR and FSR) on powder catalysts by using a comparative approach with respect to the influence of the ZrO 2 polymorph support structure (monoclinic (m-)ZrO 2 vs. tetragonal (t-)ZrO 2 ), its synthesis routine and the choice of the precursor material on the CO 2 selectivity. Our studies reveal that ZrO 2 exhibits a pronounced versatility as a support material and its catalytic properties depend most strongly on its surface properties governed by its synthesis, especially by the choice of the Zr precursor. The way of combining the support with copper introduces an additional layer of complexity, but its influence on the MSR performance is limited to a modification of the conditions provided by the ZrO 2 support. Exploiting the comparative approach regarding the Cu-ZrO 2 catalysts in FSR and MSR – including the pure support materials – in combination with in situ Fourier transform infrared (FT-IR) spectroscopy shows that the CO observed in MSR on Cu/m-ZrO 2 can be attributed to a spillover of formaldehyde to the support. Side reactions of m-ZrO 2 are suppressed at lower temperatures due to its lack of highly reactive sites, resulting in a CO 2 -selective MSR performance. In Cu/t-ZrO 2 , however, the amount of CO is higher and a combination of a formaldehyde spillover to the support and a Cu-ZrO 2 phase boundary yielding CO leads to the lower CO 2 selectivity of these samples. An elevated number of defects and reactive Lewis acidic and Brønsted basic centers of t-ZrO 2 explains this increased activity towards side reactions in contrast to Cu/m-ZrO 2 catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

The sol–gel autocombustion as a route towards highly CO 2 -selective, active and long-term stable Cu/ZrO 2 methanol steam reforming catalysts

The adaption of the sol-gel autocombustion method to the Cu/ZrO 2 system opens new pathways for the specific optimisation of the activity, long-term stability and CO 2 selectivity of methanol steam reforming (MSR) catalysts. Calcination of the same post-combustion precursor at 400 °C, 600 °C or 800 °C allows accessing Cu/ZrO 2 interfaces of metallic Cu with either amorphous, tetragonal or monoclinic ZrO 2 , influencing the CO 2 selectivity and the MSR activity distinctly different. While the CO 2 selectivity is less affected, the impact of the post-combustion calcination temperature on the Cu and ZrO 2 catalyst morphology is more pronounced. A porous and largely amorphous ZrO 2 structure in the sample, characteristic for sol-gel autocombustion processes, is obtained at 400 °C. This directly translates into superior activity and long-term stability in MSR compared to Cu/tetragonal ZrO 2 and Cu/monoclinic ZrO 2 obtained by calcination at 600 °C and 800 °C. The morphology of the latter Cu/ZrO 2 catalysts consists of much larger, agglomerated and non-porous crystalline particles. Based on aberration-corrected electron microscopy, we attribute the beneficial catalytic properties of the Cu/amorphous ZrO 2 material partially to the enhanced sintering resistance of copper particles provided by the porous support morphology.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Insights into the Mechanism of Methanol Steam Reforming Tandem Reaction over CeO 2 Supported Single-Site Catalysts

We demonstrated how the special synergy between a noble metal single site and neighboring oxygen vacancies provides an "ensemble reaction pool" for high hydrogen generation efficiency and carbon dioxide (CO 2 ) selectivity of a tandem reaction: methanol steam reforming. Specifically, the hydrogen generation rate over single site Ru 1 /CeO 2 catalyst is up to 9360 mol H 2 per mol Ru per hour (579 mL H2 g Ru -1 s -1 ) with 99.5% CO 2 selectivity. Reaction mechanism study showed that the integration of metal single site and O vacancies facilitated the tandem reaction, which consisted of methanol dehydrogenation, water dissociation, and the subsequent water gas shift (WGS) reaction. In addition, the strength of CO adsorption and the reaction activation energy difference between methanol dehydrogenation and WGS reaction play an important role in determining the activity and CO 2 selectivity. Our study paves the way for the further rational design of single site catalysts at the atomic scale. Furthermore, the development of such highly efficient and selective hydrogen evolution systems promises to deliver highly desirable economic and ecological benefits.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

A Study of How LaFeO 3 and CaTiO 3 Supports Affect the Oxidation, Hydrogenation, and Methane Steam Reforming Activity of Pt and Ni Catalysts

The structure and catalytic properties of Pt and Ni supported on thin films of LaFeO 3 and CaTiO 3 , prepared by Atomic Layer Deposition (ALD), were investigated. X-Ray diffraction (XRD) and scanning transmission electron microscopy (STEM) show that reduction at 1073 K causes Pt-Fe intermetallic compound formation for Pt/LaFeO 3 . For Pt/CaTiO 3 , 1073-K reduction induces local decomposition of the CaTiO 3 with migration of Ti to the Pt. Reduced Pt/LaFeO 3 and Pt/CaTiO 3 exhibited CO-oxidation activity similar to that for Pt supported on MgAl 2 O 4 but were much less active for propane oxidation and hydrogenation of 1-hexene and toluene. In contrast, Ni/CaTiO 3 behaved similarly to a conventional supported Ni catalyst for the methane-steam-reforming (MSR) and 1-hexene hydrogenation. There was also no evidence for local decomposition of the perovskite in the vicinity of the Ni particles. Furthermore, the results obtained in this study demonstrate that metal-perovskite interactions that affect reactivity are specific to each component.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Process Considerations for the Production of Hydrogen via Steam Reforming of Oxygenated Gases from Biomass Pyrolysis and Other Conversion Processes

Abstract In 2021, average CO 2 emissions was 9.7 g CO 2 /g H 2 produced, primarily based on steam methane reforming (SMR) technology that currently dominates hydrogen production. The substitution of natural gas (NG) and other fossil feedstocks in SMRs with renewable gases may be considered as an option for reducing greenhouse gas emissions. This analysis explores process impacts and constraints associated with the potential introduction of biogenic gases into SMRs. The results indicate that replacing NG in the fuel train of the SMR, followed by partial replacement of NG in the feed train may be a feasible approach. For the CO‐ and CO 2 ‐rich gas compositions assumed in this analysis the results indicate that feed train may accommodate up to 25 mole % of biogenic gases using allowances in existing designs and/or with small modifications, while maintaining similar hydrogen output. NG substitution in higher proportions require more major changes because of increased flow rates and heat exchange requirements in the system. Biogenic gases with lower CO 2 and higher calorific values are advantageous for NG substitution, and dry reforming using the CO 2 present in the feed gas can reduce steam consumption and increase process efficiency within limits where coking does not become a new constraint.

08 HYDROGEN↗
DOE OSTI2022

Stable Catalysts for Combined Dry and Steam Reforming of Methane and Carbon Dioxide

The specific aim of this project is to develop a comprehensive understanding of cheaper and more stable methane and carbon dioxide reforming catalysts with an optimal introduction of steam to reduce carbon deposits that typically prevent the catalytic systems from transferring to commercial implementation. The work was proposed as a two-year project with the end goal of to show a reliable catalyst system run for at least 400 hours at temperatures less than 800 °C with less than 5% loss of activity of the catalyst and a carbon monoxide to hydrogen product ratio of at least 1:1. The project went for one-year and met the end of year milestone by developing two strategies (use of a cerium co-catalyst and introducing 5% water) that reduced the carbon deposition rates by at least 20% relative to the baseline 10% NiMgAlO methane reforming of CO 2 at < 800 °C in order to shown technical feasibility of the concept.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mechanism for Acetone and Crotonaldehyde Production during Steam Reforming of Ethanol over La 0.7 Sr 0.3 MnO 3–x Perovskite: Evidence for a Shared C4 Aldol Addition Intermediate

Here a mechanistic study was conducted on the catalytic conversion of ethanol over La 0.7 Sr 0.3 MnO 3–x perovskite catalysts in the presence and absence of water. The study sought insights into the path of C–C coupling toward acetone and crotonaldehyde and also into clarifying whether the lack of previous reports of C–C coupling over La 0.7 Sr 0.3 MnO 3–x (100) could be due to a “pressure gap”. Several types of experiments were performed at 400–800 K: flow experiments with a torr range reactant gas flown over La 0.7 Sr 0.3 MnO 3–x powders; ultra-high vacuum experiments with continuous gas exposures to a La 0.7 Sr 0.3 MnO 3–x (100) single-crystal sample; and torr range continuous gas exposures to a La 0.7 Sr 0.3 MnO 3–x (100) single-crystal sample. When ethanol and water were flown over La 0.7 Sr 0.3 MnO 3–x powders at 400–800 K, the products detected were ethene, acetaldehyde, acetone, crotonaldehyde, CO, CO 2 , and H 2 . Acetone was catalytically produced over both the La 0.7 Sr 0.3 MnO 3–x powder and the La 0.7 Sr 0.3 MnO 3–x (100) single-crystal sample at temperatures of 700–800 K when reaction conditions were on the order of 1 Torr of reactant gas and with an excess of water relative to ethanol (1 ethanol/9 water). Isotopic labeling with deuterium was used to gain insights into the C–C coupling reaction mechanism and paths in species with three and four carbons (C 3 and C 4 species). Additionally, steady-state isotopic transient kinetic analysis (SSITKA) experiments + simulations using carbon labeling of the ethanol feed were performed. Three mechanistic paths were considered for the C–C coupling step: the first two paths, A and B, involve coupling between two intermediates which are both in oxygen vacancies; and the third path, C, involves coupling between one intermediate in an oxygen vacancy and one intermediate outside of an oxygen vacancy. The results suggest that the dominant path to the C 3 product, acetone, depends on the conditions. The less active path (attributed to path A or B) occurs at 600–700 K and involves coupling between two irreversibly bound species. The more active path (attributed to path C) requires an excess of water, becomes dominant at 600–800 K, and involves coupling between one irreversibly bound species and one reversibly bound species. Based on these various observations from experiments and simulations, an elementary step is proposed for acetone formation involving a previously unreported C 4 transition state that is formed after aldol addition. Density functional theory calculations were performed based on this hypothesis, and it confirmed that this specific and previously unreported aldol addition path to acetone does exist and that this path consistent with the experimental data. In this path, C–C formation occurs to create a C 4 intermediate that is bound to an oxygen vacancy, then a hydrogen transfer with C–C bond breaking occurs that results in the production of the acetone molecule. The proposed mechanism is also consistent with the experimental observation that acetone formation has a greater than first-order dependence on the water vapor pressure.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗