The strive to increase the engine efficiency in terms of fuel consumption and lower emissions have lead to higher demands on materials. In this thesis five different thermal barrier coatings applied using air plasma spraying to three materials commonly used for exhaust application are evaluated. This thesis work was done at Scania CV in Södertälje with main focus on evaluation during thermal cycling. The goal of this thesis is to evaluate the coatings and correlate their behaviour to their characteristic microstructure. The coatings were evaluated through their stability in thermal conductivity, fracture toughness, hardness, porosity and failure modes. The parameters where obtained using laser flash, Vickers indentation, Vickers indentation fracture toughness and microscopic evaluation methods. The evaluation shows that conventionally used zirconia based materials exhibits low thermal conductivity, high hardness, and stable fracture toughness compared to other evaluated materials. One material that can be applicable in diesel exhaust application is mullite, which showed similar performance to zirconia based materials. For the use of TBC together with SiMo51 a different bondcoat than conventional NiCrAlY needs to be evaluated. / Strävan efter att konstruera effektivare motorer för att generera minskade utsläpp och bättre bränsleekonomi har genererat högre krav på konstruktionsmaterialen som används idag. I detta examensarbete som utförts på Scania CV i Södertälje utvärderas fem olika termiska barriärsskikt som belagts med plasma sprayning på tre vanligt förekommande konstruktionsmaterial för grenrör. Målet med detta examensarbete är att utvärdera beläggningarnas beteende under termisk cykling och koppla deras beteende till karakteristiska mikrostrukturer. Beläggningarna utvärderades genom att jämföra deras värmeledningsförmåga, hårdhet, brottseghet och porositet. Materialparametrarna utvärderades genom laser flash, Vickers hårdhetsmätning, Vickers brottseghet samt mikroskopiska bildanalyser. Resultaten visar att kommersiellt använda zirkonium baserade material uppvisar låg värmeledningsförmåga, hög hårdhet och hög brottseghet i förhållande till övriga material. Ett annat material som analyserats, mullit, visar på liknande beteenden som zirkonium baserade material men behöver utvärderas ytterligare. Om SiMo51 används som substratmaterial finns behovet att utvärdera användningen av andra typer av bindskikt än det austenitiska NiCrAlY nu använt.

Yttria stabilized zirconia (YSZ) coatings were produced from a YSZ suspension in acetylacetone (ACAC) using electrophoretic deposition (EPD) and then consolidated via the natural drying and isothermal sintering with the constraint of the metal substrates. Before EPD, the operational pH of the suspension was adjusted by addition of acetic acid or organic bases. The effect of suspension pH on the deposition of EPD coatings was studied with respect to the suspension stability, coating density and microstructure both for a mono-sized system and micro-nano binary systems. The constrained drying process of the deposits was examined via the measurement of the critical cracking thickness (CCT). The sinterability of coatings was evaluated by micro-hardness and microstructure. For a mono-sized (0.26μm) suspension, results showed that the zeta potential had a high positive value on both sides of the isoelectric point (IEP). This probably resulted from the adsorption of base molecules triethanolamine (TEA), detected by fourier transform infrared spectroscopy. Three alkalis with different molecular structure were compared and the effect of their molecule length on the interparticle repulsion was discussed. Accordingly, the double layer thickness of the particles can be estimated. Based on this, particle interactions were estimated for different pH suspensions. The reduced particle coagulation increased the packing density of the EPD coatings from 38 % at pH 7.4 to 53 % at pH 8.4. Therefore, subsequent sintering of coatings was promoted. After sintering at 1200 °C, coatings made in pH 8.4 suspensions obtained a much higher hardness and had fewer big pores than coatings fabricated in pH 7.4 suspensions. The CCT of the latter is slightly higher than the former which might be ascribed to its particle network structure. In a binary suspension composed of the coarse (1μm) and fine (with average size of 100 nm or 10 nm, content varied in 0-30 wt. % to the powder mixture) YSZ powders, interactions between different species can be tuned by the zeta potential of individual component. Binary particles can be well dispersed at pH 4 when both of the coarse and fine powders reached their highest zeta potentials. Heterocoagulation occurred between them to form a haloing structure with fine powders covered on the coarse particle surfaces when they exhibited zeta potentials of the opposite sign at pH 8.6. Particle interactions were estimated and the microstructures of the binary coatings were examined to discuss how the different fine particle sizes influenced the particle packing after EPD. At pH 4, there existed a “stability window” for the 10 nm fines at 10 wt. % whereas no noticeable the border of the window can be observed for 100 nm fines within the measuring range. 10 nm and 100 nm fine powders gave similar overall densities of binary EPD coatings which were independent of the fine powder content. For heterocoagulation coatings made at pH 8.6, although the adsorption of fine particles reduce the agglomeration of coarse powder, the low zeta potential of the halos led to a loose structure of the “skeleton” ( the packing of the coarse powder) in the final binary coatings. 10 nm fine powders was observed to give a higher CCT and denser particle packing than 100 nm fine powders especially in a pre-saturated heterocoagulated binary coatings at 20 wt. % fine powder content. In order to further improve the sintering of the EPD coatings at low temperature sintering, a layer of CuO was applied on the coarse powder surface. With the addition of 30 wt. % fine powders, the hardness of EPD coatings after sintering 2 hours at 1150°C increased from 6 to 61 Vickers. With the presence of CuO, the hardness values were enhanced by 2.5-4.25 times. The density measurements indicated that the CuO layer not only served as a sintering aid, the CuO layer also helped with the binary particle packing particularly in the heterocoagulation condition because of the stronger particle interactions between the fine powders and CuO modified coarse powders. It seems that CuO had no significant impact on the cracking resistance of the binary coatings during drying, however t-m phase transformation was observed during sintering possibly due to the liquid phase induce by CuO.

No description available.

Neste trabalho, investigou-se a atividade catalítica de materiais a base de Ni/YSZ modificados com Rh ou Ru a 0,5%, 1% e 3%, para a reforma a vapor de etanol (RVE) e seus desempenhos como eletrocatalisadores em células a combustível de óxido sólido (SOFCs - Solid Oxide Fuel Cell). Os catalisadores foram preparados pelo método Pechini e de impregnação. A caracterização estrutural foi realizada utilizando-se as técnicas de Energia Dispersiva de Raios X, Difratometria de Raios X, Redução à Temperatura Programada, Fisissorção de Nitrogênio, Microscopia Eletrônica de Varredura e Análise Elementar. Os testes catalíticos foram realizados a 700 e 900 °C, em uma linha de reação acoplada a um cromatógrafo a gás para o monitoramento dos produtos reacionais gasosos. Os produtos líquidos resultantes da RVE foram analisados por Cromatografia Líquida de Alta Eficiência (CLAE). O objetivo principal foi correlacionar a estrutura e a composição destes materiais com a produção de H2, distribuição de outros produtos reacionais e formação de depósitos de carbono. Os resultados obtidos mostraram que a incorporação de Rh ou Ru no catalisador de Ni/YSZ não resultou em mudanças significativas na estrutura e atividade catalítica, porém promoveu uma diminuição na quantidade de carbono formado, sendo mais expressiva para o caso da adição de Rh. O aumento da temperatura de reação de 700 °C para 900 °C resultou em um aumento da seletividade dos catalisadores para os produtos gasosos e diminuição da formação de coque. O estudo em uma célula unitária de SOFC foi conduzido utilizando-se platina no cátodo e 3%Rh/40%Ni/YSZ(P) no ânodo, em uma célula operando com H2 e ar a 900 °C. Embora as curvas de polarização tenham apresentado baixas densidades de potência, os resultados mostraram que o material de 3%Rh/40%Ni/YSZ(P) foi ativo para a produção e eletro-oxidação de H2 em condições reais de operação das SOFCs. Além disso, mostrou-se que é possível investigar a atividade de eletrocatalisadores de ânodos de SOFC para a reforma de etanol em linhas de reação comumente utilizadas em estudos de catálise heterogênea. / In this work, it was investigated the electrocatalytic activity of Ni/YSZ promoted with Rh or Ru (0.5 wt%, 1.0 wt% and 3.0 wt% content) for the Ethanol Steam Reforming (ESR) reaction, and their performance as electrocatalysts in Solid Oxide Fuel Cells (SOFCs). The catalysts were prepared by the Pechini and Impregnation methods. The material characterization was carried out by Energy Dispersive X-ray (EDX), X-ray Diffraction (DRX), Temperature Programmed Reduction (TPR-H2), N2 physisorption, Scanning Electron Microscopy (SEM), and Elemental Analysis. The catalytic tests were performed at 700 and 900 °C in a reaction system coupled to a gas chromatograph in order to monitor the gaseous products. The liquid products were analyzed by High Performance Liquid Chromatography (HPLC). The structure and composition of these catalysts were correlated to the H2 formation, with the distribution of other parallel reaction products, including the carbon deposition. The obtained results showed that the incorporation of Rh or Ru does not change significantly the structure and catalytic activity, but it decreases the carbon deposits, being more significant for the addition of Rh. The increase of the reaction temperature from 700 °C to 900 °C increased the gaseous products selectivities and decreased the carbon deposition. The study in SOFC unit cells were conducted using platinum and 3%Rh/40%Ni/YSZ(P) in the cathode and anode, respectively. The SOFC operated with H2 and air, and 900 °C. Although the polarization curves have presented low power densities, the obtained results showed that the 3%Rh/40%Ni/YSZ(P) electrocatalyst was active for the H2 production and eletro-oxidation in the SOFC real operation conditions. Furthermore, the results have demonstrated that it is possible to investigate SOFC electrocatalysts activity for the ethanol steam reforming in reaction lines commonly utilized in heterogeneous catalysis studies.

Neste trabalho, investigou-se a atividade catalítica de materiais a base de Ni/YSZ modificados com Rh ou Ru a 0,5%, 1% e 3%, para a reforma a vapor de etanol (RVE) e seus desempenhos como eletrocatalisadores em células a combustível de óxido sólido (SOFCs - Solid Oxide Fuel Cell). Os catalisadores foram preparados pelo método Pechini e de impregnação. A caracterização estrutural foi realizada utilizando-se as técnicas de Energia Dispersiva de Raios X, Difratometria de Raios X, Redução à Temperatura Programada, Fisissorção de Nitrogênio, Microscopia Eletrônica de Varredura e Análise Elementar. Os testes catalíticos foram realizados a 700 e 900 °C, em uma linha de reação acoplada a um cromatógrafo a gás para o monitoramento dos produtos reacionais gasosos. Os produtos líquidos resultantes da RVE foram analisados por Cromatografia Líquida de Alta Eficiência (CLAE). O objetivo principal foi correlacionar a estrutura e a composição destes materiais com a produção de H2, distribuição de outros produtos reacionais e formação de depósitos de carbono. Os resultados obtidos mostraram que a incorporação de Rh ou Ru no catalisador de Ni/YSZ não resultou em mudanças significativas na estrutura e atividade catalítica, porém promoveu uma diminuição na quantidade de carbono formado, sendo mais expressiva para o caso da adição de Rh. O aumento da temperatura de reação de 700 °C para 900 °C resultou em um aumento da seletividade dos catalisadores para os produtos gasosos e diminuição da formação de coque. O estudo em uma célula unitária de SOFC foi conduzido utilizando-se platina no cátodo e 3%Rh/40%Ni/YSZ(P) no ânodo, em uma célula operando com H2 e ar a 900 °C. Embora as curvas de polarização tenham apresentado baixas densidades de potência, os resultados mostraram que o material de 3%Rh/40%Ni/YSZ(P) foi ativo para a produção e eletro-oxidação de H2 em condições reais de operação das SOFCs. Além disso, mostrou-se que é possível investigar a atividade de eletrocatalisadores de ânodos de SOFC para a reforma de etanol em linhas de reação comumente utilizadas em estudos de catálise heterogênea. / In this work, it was investigated the electrocatalytic activity of Ni/YSZ promoted with Rh or Ru (0.5 wt%, 1.0 wt% and 3.0 wt% content) for the Ethanol Steam Reforming (ESR) reaction, and their performance as electrocatalysts in Solid Oxide Fuel Cells (SOFCs). The catalysts were prepared by the Pechini and Impregnation methods. The material characterization was carried out by Energy Dispersive X-ray (EDX), X-ray Diffraction (DRX), Temperature Programmed Reduction (TPR-H2), N2 physisorption, Scanning Electron Microscopy (SEM), and Elemental Analysis. The catalytic tests were performed at 700 and 900 °C in a reaction system coupled to a gas chromatograph in order to monitor the gaseous products. The liquid products were analyzed by High Performance Liquid Chromatography (HPLC). The structure and composition of these catalysts were correlated to the H2 formation, with the distribution of other parallel reaction products, including the carbon deposition. The obtained results showed that the incorporation of Rh or Ru does not change significantly the structure and catalytic activity, but it decreases the carbon deposits, being more significant for the addition of Rh. The increase of the reaction temperature from 700 °C to 900 °C increased the gaseous products selectivities and decreased the carbon deposition. The study in SOFC unit cells were conducted using platinum and 3%Rh/40%Ni/YSZ(P) in the cathode and anode, respectively. The SOFC operated with H2 and air, and 900 °C. Although the polarization curves have presented low power densities, the obtained results showed that the 3%Rh/40%Ni/YSZ(P) electrocatalyst was active for the H2 production and eletro-oxidation in the SOFC real operation conditions. Furthermore, the results have demonstrated that it is possible to investigate SOFC electrocatalysts activity for the ethanol steam reforming in reaction lines commonly utilized in heterogeneous catalysis studies.

Cerâmicas de zircônia estabilizada com ítria são utilizadas na forma densa como eletrólito e na forma porosa como ânodo em células a combustível de óxido sólido. Neste trabalho cerâmicas porosas de zircônia estabilizada com 8 mol% de ítria foram preparadas por meio da adição de diferentes teores de KI, NaCl e grafite como aditivo sacrificial. A remoção térmica do aditivo foi avaliada por meio de análises termogravimétrica, térmica diferencial e dilatométrica. As amostras foram preparadas por meio de mistura, compactação e sinterização a 1400 ºC/2 h. As amostras foram caracterizadas por difração de raios X(DRX) e análise topográfica em microscópio de varredura por sonda e microscópio eletrônico de varredura de superfícies polidas e atacadas para avaliação da distribuição do teor de poros e tamanho médio de grãos. O teor do aditivo residual foi avaliado por fluorescência de raios X (FRX). O comportamento elétrico foi analisado por espectroscopia de impedância (EI) na faixa de frequências 5 Hz-10 MHz entre 300 ºC e 450 ºC. Os resultados de FRX mostram que não há resíduo do aditivo após sinterização. A análise de DRX indica que todas as amostras têm fase única, cúbica tipo fluorita. Os diagramas de impedância mostram que há aumento i) das resistividades elétricas intergranular e intragranular, evidenciando a formação de poros em ambas as regiões, ii) do ângulo de descentralização do semicírculo a baixas frequências, devido ao aumento do grau de heterogeneidade pela presença de poros, e iii) do produto do fator de bloqueio R pelo fator de frequência f, consequência do aumento do teor de poros. Esses resultados estão em concordância com os resultados das análises de microscopia de varredura por sonda e de microscopia eletrônica de varredura. / Dense and porous yttria-stabilized zirconia ceramics are used as electrolytes and anodes, respectively, in solid oxide fuel cells. Porous ZrO2: 8 mol% Y2O3 (8YSZ) were prepared by using NaCl, KI and graphite as sacrificial additives. The thermal removal of the additives was evaluated by thermogravimetry, differential thermal analysis and dilatometry. The samples were prepared by thoroughly mixing 8YSZ to the additives, pressing and sintering at 1400 ºC/2 h. The samples were characterized by X-ray diffraction (XRD) and by observation of polished and etched surfaces in scanning probe microscope (SPM) and scanning electron microscope (FEG-SEM) to evaluate pore content. The evaluation of the NaCl and KI content was carried out by X-ray fluorescence (XRF) analysis. The electrical behavior was analyzed by impedance spectroscopy (IS) in the 5 Hz-10 MHz frequency range from 300 ºC to 450 ºC. The XRF results show no remaining KI or NaCl in the sintered samples. The XRD patterns show all samples are single cubic fluorite phase. The IS plots show that there is an increase i) of the intergranular and the intragranular electrical resistivity, an indication of bulk and grain boundary pore formation, ii) of the decentralization angle of the grain boundary semicircle in the impedance plots due to increasing heterogeneity of the samples, and iii) of the product of the blocking factor R to the frequency factor f, as a consequence of the increase in pore content. These results are in agreement with the SPM and SEM observations.

Este estudo visa a definição de condições de síntese e processamento cerâmico que possibilitem a obtenção do componente anódico com características adequadas para a operação de uma SOFC (Solid Oxide Fuel Cell), ou seja, boa distribuição microestrutural do NiO na matriz de YSZ e porosidade cerca de 30% após redução de NiO. As rotas de síntese selecionadas englobaram a coprecipitação em meio amoniacal, mistura mecânica dos pós e combustão a partir de sais de nitrato. As técnicas de caracterização de pós empregadas incluíram a difração de raios X, microscopia eletrônica de varredura, microscopia eletrônica de transmissão, difração a laser, adsorção gasosa (BET) e picnometria de hélio. Os resultados obtidos indicaram que empregando-se a técnica de coprecipitação, a perda de Ni2+, na forma de complexo [Ni(NH3)n]2+, pode ser minimizada pelo controle do pH em 9,3, mantendo-se a concentração de Ni2+ na solução inicial em 0,1M. No método de mistura mecânica a melhor condição de dispersão dos pós, sem a sedimentação diferencial, foi obtida para valores de potencial zeta em pH 8,0, fixando-se a concentração de dispersante em 0,8% em massa. Na síntese por combustão observou-se que para composições pobres em combustível, os produtos finais apresentaram-se amorfos e com alta área superficial (120,2 m2.g-1). Para as composições ricas em combustível, uréia, os pós obtidos apresentaram-se cristalinos sendo que a intensidade das reflexões do padrão de DRX aumenta com o aumento do excesso de combustível, devido ao aumento da temperatura de reação. No estudo de sinterabilidade dos compactados preparados a partir de pós preparados pelos três métodos determinou-se a temperatura ao redor de 1300 ºC para máxima taxa de densificação e porosidade entre 6,0 e 14%. Os resultados da redução em atmosfera de H2 dos compósitos confirmam que a cinética de reação ocorre em duas etapas, sendo que a primeira etapa com comportamento linear é controlada por reação química na superfície. Na segunda etapa a redução passa a ser controlada pela difusão do gás nos micros poros, gerados pela redução do NiO, diminuindo a taxa de redução. / This study aim the definition of synthesis and ceramic processing conditions of the anodic component suitable for operation of SOFC, i.e, homogeneous distribution of NiO in YSZ matrix and porosity after reduction above 30%. The selected synthesis routes included the co-precipitation in ammonia media, mechanical mixing of powders and combustion reaction from nitrate salts. The characterization techniques of powders included the X-ray diffraction, scanning and transmission electron microscopy, laser diffraction, nitrogen gas adsorption technique (BET) and Helium pycnometry. The obtained results indicated that the loss of Ni2+ in co-precipitation process, due to the formation of complex [Ni(NH3)n]2+, can be minimized by controlling the pH around 9.3, keeping the concentration of nickel cation in the solution to be precipitated around 0.1M. In the mechanical mixing method the best condition of powder dispersion, without differential sedimentation, was obtained for zeta potential values at pH around 8.0, fixing the dispersant concentration at 0.8%. For the combustion synthesis it was observed that when stoichiometric and twofold stoichiometric urea was used, amorphous phase was formed and a higher surface area was attained in the final products. Employing the fuel-rich solution condition, crystallization of the powder was observed and the relative intensity of reflections of XRD patterns increased with excess of fuel, due to increasing the reaction temperature. Sinterability studies of pellets prepared from powder synthesized by the three routes described above showed the temperature around 1300 º C for maximum rate densification and porosity between 6.0 and 14%. Reduction results of the composites confirmed that the reduction kinetics occurs in two steps. The first one with a linear behavior and controlled by chemical reaction on the surface. The second reduction step is the reduction that is controlled by gas diffusion in micro pores, generated by reduction of nickel oxide, decreasing the rate of reduction.

Este estudo visa a definição de condições de síntese e processamento cerâmico que possibilitem a obtenção do componente anódico com características adequadas para a operação de uma SOFC (Solid Oxide Fuel Cell), ou seja, boa distribuição microestrutural do NiO na matriz de YSZ e porosidade cerca de 30% após redução de NiO. As rotas de síntese selecionadas englobaram a coprecipitação em meio amoniacal, mistura mecânica dos pós e combustão a partir de sais de nitrato. As técnicas de caracterização de pós empregadas incluíram a difração de raios X, microscopia eletrônica de varredura, microscopia eletrônica de transmissão, difração a laser, adsorção gasosa (BET) e picnometria de hélio. Os resultados obtidos indicaram que empregando-se a técnica de coprecipitação, a perda de Ni2+, na forma de complexo [Ni(NH3)n]2+, pode ser minimizada pelo controle do pH em 9,3, mantendo-se a concentração de Ni2+ na solução inicial em 0,1M. No método de mistura mecânica a melhor condição de dispersão dos pós, sem a sedimentação diferencial, foi obtida para valores de potencial zeta em pH 8,0, fixando-se a concentração de dispersante em 0,8% em massa. Na síntese por combustão observou-se que para composições pobres em combustível, os produtos finais apresentaram-se amorfos e com alta área superficial (120,2 m2.g-1). Para as composições ricas em combustível, uréia, os pós obtidos apresentaram-se cristalinos sendo que a intensidade das reflexões do padrão de DRX aumenta com o aumento do excesso de combustível, devido ao aumento da temperatura de reação. No estudo de sinterabilidade dos compactados preparados a partir de pós preparados pelos três métodos determinou-se a temperatura ao redor de 1300 ºC para máxima taxa de densificação e porosidade entre 6,0 e 14%. Os resultados da redução em atmosfera de H2 dos compósitos confirmam que a cinética de reação ocorre em duas etapas, sendo que a primeira etapa com comportamento linear é controlada por reação química na superfície. Na segunda etapa a redução passa a ser controlada pela difusão do gás nos micros poros, gerados pela redução do NiO, diminuindo a taxa de redução. / This study aim the definition of synthesis and ceramic processing conditions of the anodic component suitable for operation of SOFC, i.e, homogeneous distribution of NiO in YSZ matrix and porosity after reduction above 30%. The selected synthesis routes included the co-precipitation in ammonia media, mechanical mixing of powders and combustion reaction from nitrate salts. The characterization techniques of powders included the X-ray diffraction, scanning and transmission electron microscopy, laser diffraction, nitrogen gas adsorption technique (BET) and Helium pycnometry. The obtained results indicated that the loss of Ni2+ in co-precipitation process, due to the formation of complex [Ni(NH3)n]2+, can be minimized by controlling the pH around 9.3, keeping the concentration of nickel cation in the solution to be precipitated around 0.1M. In the mechanical mixing method the best condition of powder dispersion, without differential sedimentation, was obtained for zeta potential values at pH around 8.0, fixing the dispersant concentration at 0.8%. For the combustion synthesis it was observed that when stoichiometric and twofold stoichiometric urea was used, amorphous phase was formed and a higher surface area was attained in the final products. Employing the fuel-rich solution condition, crystallization of the powder was observed and the relative intensity of reflections of XRD patterns increased with excess of fuel, due to increasing the reaction temperature. Sinterability studies of pellets prepared from powder synthesized by the three routes described above showed the temperature around 1300 º C for maximum rate densification and porosity between 6.0 and 14%. Reduction results of the composites confirmed that the reduction kinetics occurs in two steps. The first one with a linear behavior and controlled by chemical reaction on the surface. The second reduction step is the reduction that is controlled by gas diffusion in micro pores, generated by reduction of nickel oxide, decreasing the rate of reduction.

As a means to produce high pressure hydrogen in order to reduce compression penalty, we propose to reform liquid fuel (e.g., bio-ethanol) in supercritical water (pressure above 221 bar and temperature greater than 374°C). Catalytic ethanol reforming in supercritical water for hydrogen production has been carried out in a high pressure packed bed reactor made of Inconel-625. Since Inconel-625 contains mainly nickel, it is expected that the reactor itself can be active toward ethanol reforming. Therefore, a series of tests were first performed in the empty reactor, whose results are a benchmark when studying reforming in the presence of a catalyst. Ethanol reforming in the empty reactor was studied in the temperature range of 450 to 600°C and showed coking/plugging problem at 575°C and above. The ethanol conversion with the empty reactor could be as high as 25% at 550°C and residence time of about one minute. The main reaction products with the empty reactor were H2, CO and CH4. A catalyst screening study was performed to investigate the performance of nickel and cobalt as active metals, supported on γ-Al2O3, α-Al2O3, ZrO2 and YSZ for temperatures between 475°C and 550°C. The presence of the catalyst did increase the activity of ethanol reforming, especially at higher temperatures. All experiments in the catalyst screening study were carried out with non-reduced catalysts. Nickel catalysts were found more active than cobalt, likely because of higher reducibility. Indeed, the higher amount of oxygen in Co3O4 compared to NiO requires more hydrogen to fully reduce the metal oxides. Both Ni/γ-Al2O3 and Co/γ-Al2O3 showed little activity below 500°C, and led to failed experiments due to coking/plugging at temperatures of 525°C and above. The strong acid sites on γ-Al2O3 are responsible for high selectivity toward ethylene, a known coke precursor. The support α-Al2O3 in combination with Ni was active, but yielded lower H2 selectivity and higher CH4 selectivity than the zirconia-based catalysts. The Co/α-Al2O3 shows low activity. The ZrO2-based catalysts were active and yielded high H2 selectivity, but were found very fragile. Finally, the YSZ support was strong and yielded good conversion. Below 550°C the activity of Ni/YSZ is higher than that of Co/YSZ, but at 550°C both catalysts yield nearly complete conversion. The advantage of Co/YSZ is then higher H2 selectivity and lower CH4 selectivity compared to Ni/YSZ. Therefore, Co/YSZ was selected for a more detailed study. The effect of temperature, flowrate, residence time, catalyst weight, Co loading, concentration, and pretreatment with H2 were considered. Two methods for catalyst reduction were applied: ex-situ reduction where the catalyst is reduced in a different reactor and in-situ reduction where the catalyst is reduced in the SCW reactor prior to ethanol reforming. At 550°C, Co/YSZ converts all ethanol for residence times as low as 2 s, even with non-reduced catalyst. At 500°C the activity of the in-situ and ex-situ reduced catalysts were similar and greater than for the non-reduced catalyst. At 475°C the ex-situ reduced catalyst showed low activity, comparable to that of the non-reduced catalyst, but the in-situ reduced catalyst yielded much higher conversion. The better performance of the in-situ reduced catalyst was attributed to active metal sites on the reactor’s wall after pre-treatment in H2. The low activity of the ex-situ reduced catalyst is due to the fact that, when exposed to supercritical water for less than 30 minutes, it re-oxidized to CoO. The temperature of 475°C is then too low to generate sufficient hydrogen that will start reducing the catalyst. Finally, analysis of reaction pathways for ethanol reforming over Co/YSZ showed that the reaction proceeds mostly via ethanol dehydrogenation to form acetaldehyde, the latter species reacting with lattice oxygen on the catalyst to produce acetone and CO2. Acetone is then reformed by water into CO and H2. Finally, H2 and CO react via the methanation reaction to form CH4. Over Co/YSZ it was found that the water-gas shift reaction is fast (CO selectivity most of the time is less than 0.5%), but the methanation reaction is kinetically controlled. Stopping the methanation reaction before equilibrium allowed for H2 selectivity higher than what is expected at equilibrium (likewise, CH4 selectivity is smaller than equilibrium value). For well-controlled reaction Co/YSZ is a promising catalyst that can be highly selective toward hydrogen during ethanol reforming in supercritical water.

As a means to produce high pressure hydrogen in order to reduce compression penalty, we propose to reform liquid fuel (e.g., bio-ethanol) in supercritical water (pressure above 221 bar and temperature greater than 374°C). Catalytic ethanol reforming in supercritical water for hydrogen production has been carried out in a high pressure packed bed reactor made of Inconel-625. Since Inconel-625 contains mainly nickel, it is expected that the reactor itself can be active toward ethanol reforming. Therefore, a series of tests were first performed in the empty reactor, whose results are a benchmark when studying reforming in the presence of a catalyst. Ethanol reforming in the empty reactor was studied in the temperature range of 450 to 600°C and showed coking/plugging problem at 575°C and above. The ethanol conversion with the empty reactor could be as high as 25% at 550°C and residence time of about one minute. The main reaction products with the empty reactor were H2, CO and CH4. A catalyst screening study was performed to investigate the performance of nickel and cobalt as active metals, supported on γ-Al2O3, α-Al2O3, ZrO2 and YSZ for temperatures between 475°C and 550°C. The presence of the catalyst did increase the activity of ethanol reforming, especially at higher temperatures. All experiments in the catalyst screening study were carried out with non-reduced catalysts. Nickel catalysts were found more active than cobalt, likely because of higher reducibility. Indeed, the higher amount of oxygen in Co3O4 compared to NiO requires more hydrogen to fully reduce the metal oxides. Both Ni/γ-Al2O3 and Co/γ-Al2O3 showed little activity below 500°C, and led to failed experiments due to coking/plugging at temperatures of 525°C and above. The strong acid sites on γ-Al2O3 are responsible for high selectivity toward ethylene, a known coke precursor. The support α-Al2O3 in combination with Ni was active, but yielded lower H2 selectivity and higher CH4 selectivity than the zirconia-based catalysts. The Co/α-Al2O3 shows low activity. The ZrO2-based catalysts were active and yielded high H2 selectivity, but were found very fragile. Finally, the YSZ support was strong and yielded good conversion. Below 550°C the activity of Ni/YSZ is higher than that of Co/YSZ, but at 550°C both catalysts yield nearly complete conversion. The advantage of Co/YSZ is then higher H2 selectivity and lower CH4 selectivity compared to Ni/YSZ. Therefore, Co/YSZ was selected for a more detailed study. The effect of temperature, flowrate, residence time, catalyst weight, Co loading, concentration, and pretreatment with H2 were considered. Two methods for catalyst reduction were applied: ex-situ reduction where the catalyst is reduced in a different reactor and in-situ reduction where the catalyst is reduced in the SCW reactor prior to ethanol reforming. At 550°C, Co/YSZ converts all ethanol for residence times as low as 2 s, even with non-reduced catalyst. At 500°C the activity of the in-situ and ex-situ reduced catalysts were similar and greater than for the non-reduced catalyst. At 475°C the ex-situ reduced catalyst showed low activity, comparable to that of the non-reduced catalyst, but the in-situ reduced catalyst yielded much higher conversion. The better performance of the in-situ reduced catalyst was attributed to active metal sites on the reactor’s wall after pre-treatment in H2. The low activity of the ex-situ reduced catalyst is due to the fact that, when exposed to supercritical water for less than 30 minutes, it re-oxidized to CoO. The temperature of 475°C is then too low to generate sufficient hydrogen that will start reducing the catalyst. Finally, analysis of reaction pathways for ethanol reforming over Co/YSZ showed that the reaction proceeds mostly via ethanol dehydrogenation to form acetaldehyde, the latter species reacting with lattice oxygen on the catalyst to produce acetone and CO2. Acetone is then reformed by water into CO and H2. Finally, H2 and CO react via the methanation reaction to form CH4. Over Co/YSZ it was found that the water-gas shift reaction is fast (CO selectivity most of the time is less than 0.5%), but the methanation reaction is kinetically controlled. Stopping the methanation reaction before equilibrium allowed for H2 selectivity higher than what is expected at equilibrium (likewise, CH4 selectivity is smaller than equilibrium value). For well-controlled reaction Co/YSZ is a promising catalyst that can be highly selective toward hydrogen during ethanol reforming in supercritical water.