Catalyst structure for synthesis gas production, synthesis gas production apparatus, and method for producing catalyst structure for synthesis gas production
A catalyst structure for synthesis gas production of a synthesis gas that contains carbon monoxide and hydrogen, the catalyst structure being provided with a carrier that has a porous structure, while being configured from a zeolite type compound; first catalyst particles that contain one or more iron group elements which are selected from the group consisting of nickel (Ni), iron (Fe) and cobalt (Co); and second catalyst particles that contain one or more platinum group elements which are selected from the group consisting of platinum (Pt), palladium (Pd), rhodium (Rh) and ruthenium (Ru). The catalyst structure for synthesis gas production has passages in communication with each other within the carrier. The first catalyst particles are present at least in the passages of the carrier; and the second catalyst particles are present at least either inside the carrier or on the outer surface of the carrier.
1 . A syngas production catalyst structure for use in production of a syngas comprising carbon monoxide and hydrogen, the syngas production catalyst structure comprising:
a support comprising a zeolite compound and having a porous structure;
first catalyst particles comprising at least one iron group element selected from the group consisting of nickel (Ni), iron (Fe), and cobalt (Co); and
second catalyst particles comprising at least one platinum group element selected from the group consisting of platinum (Pt), palladium (Pd), rhodium (Rh), and ruthenium (Ru), wherein
the support has, in its interior, channels communicating with one another,
the first catalyst particles are present at least in the channels of the support,
the second catalyst particles are present at least either inside the support or on an outer surface of the support, and
the first catalyst particles have an average particle size larger than an average inner diameter of the channels.
2 . The syngas production catalyst structure according to claim 1 , wherein the at least one iron group element is nickel (Ni).
3 . The syngas production catalyst structure according to claim 1 , wherein a total content of the first catalyst particles is 0.5% by mass or more and 3.5% by mass or less with respect to a mass of the syngas production catalyst structure.
4 . The syngas production catalyst structure according to claim 1 , wherein the first catalyst particles have an average particle size in a range of 1.0 nm or more and 13.0 nm or less.
5 . The syngas production catalyst structure according to claim 1 , wherein a ratio of an average particle size of the first catalyst particles to the average inner diameter of the channels is in a range of more than 1 and 130 or less.
6 . The syngas production catalyst structure according to claim 1 , wherein a total content of the second catalyst particles is 0.02% by mass or more and 6.00% by mass or less with respect to a mass of the syngas production catalyst structure.
7 . The syngas production catalyst structure according to claim 1 , wherein
the second catalyst particles are present on the outer surface of the support, and
the second catalyst particles present on the outer surface of the support have an average particles size in a range of 1 nm or more and 100 nm or less.
8 . The syngas production catalyst structure according to claim 1 , wherein
the second catalyst particles are present inside the support, and
the second catalyst particles present inside the support have an average particle size larger than the average inner diameter of the channels.
9 . The syngas production catalyst structure according to claim 1 , wherein the second catalyst particles are present inside the support, and
the second catalyst particles present inside the support have an average particle size in a range of 0.3 nm or more and 13.0 nm or less.
10 . The syngas production catalyst structure according to claim 1 , wherein
the channels have: any one selected from a one-dimensional pore, a two-dimensional pore, and a three-dimensional pore of a framework structure of the zeolite compound; and enlarged pore portions different from all of the one-, two-, and three-dimensional pores, and
among the first and second catalyst particles, at least the first catalyst particles are present in the enlarged pore portions.
11 . The syngas production catalyst structure according to claim 10 , wherein the first and second catalyst particles are present in the enlarged pore portions.
12 . The syngas production catalyst structure according to claim 10 , wherein the enlarged pore portions connect a plurality of pores constituting one selected from the one-, two-, and three-dimensional pores.
13 . The syngas production catalyst structure according to claim 10 , wherein the first and second catalyst particles present inside the support have an average particle size smaller than or equal to inner diameters of the enlarged pore portions.
14 . The syngas production catalyst structure according to claim 10 , wherein all of the first and second catalyst particles are metal fine particles.
15 . The syngas production catalyst structure according to claim 1 , further comprising at least one type of additional catalyst particles that are other than the first and second catalyst particles and supported on the outer surface of the support.
16 . The syngas production catalyst structure according to claim 15 , wherein a total content of the first and second catalyst particles present inside the support is higher than that of the additional catalyst particles.
17 . The syngas production catalyst structure according to claim 1 , wherein the zeolite compound is a silicate compound.
18 . The syngas production catalyst structure according to claim 1 , wherein the syngas production catalyst structure is capable of exhibiting a CH 4 conversion rate of 60% or more when loaded in an atmospheric pressure flow reactor, supplied with a raw material gas with a CH 4 /CO 2 volume ratio of 1.0, and used to perform a dry reforming reaction at 700° C. and a gas hourly space velocity (GHSV) of 320 h −1 for 100 hours from start of supply of the raw material gas.
19 . The syngas production catalyst structure according to claim 1 , wherein the zeolite compound is at least one selected from the group consisting of MTW type, MFI type, FER type, LTA type (Linde Type A), MOR type, and LTL type (Linde Type L).
20 . A syngas production system comprising the syngas production catalyst structure according to claim 1 .