Industrial waste-based Ni-catalysts for ammonia decomposition to produce clean hydrogen

The high mineral containing solid waste materials generated during aluminum production currently lacks any practical application. In this work, the potential of solid waste with/without additional nickel loading (10 to 20 wt%) was investigated as an active catalyst for low temperature ammonia decomposition to produce high purity hydrogen. The X-ray diffraction (XRD) analysis of the samples reveals that iron oxide was the primary component of solid waste with the ability to catalyze the ammonia decomposition reaction. The reducibility, metal support interaction and catalytic activity of the solid waste supported Ni-based catalysts were correlated by the reduction kinetics of the catalysts using temperature-programmed reduction (H2-TPR) data and nucleation/nuclei growth models. Based on the statistical indicators, it was concluded that the random nucleation model describes catalyst reduction adequately. The estimated activation energy for the reduction of the solid waste itself was significantly higher (108.5 kJ/mol) than that of solid waste supported catalyst containing 10 wt% Ni (86.6 kJ/mol). The increase in nickel loading also slightly decreased the activation energy of catalyst reduction, indicating an improvement in the reducibility of the nickel-containing catalysts. These reduction behaviors were also reflected in the ammonia decomposition reaction in a flow reactor. The addition of nickel onto the solid waste resulted in the creation of additional active nickel sites. Consequently, the nickel loaded solid waste supported catalysts exhibited significant improvements in ammonia decomposition activity. Among the three solid waste supported Ni-based catalysts, the catalyst containing 15 wt% Ni displayed the highest activity, that also remained unchanged over extended period, indicating the catalyst stability.