2.2.1. Thermodynamic Analysis of Steam Reforming of Model Compounds
According to thermodynamic predictions, the complete conversion of each of the model compounds through steam reforming is reached at equilibrium in the whole temperatures range from 300 to 1000 °C.
Figure 2 shows the equilibrium composition of the outlet stream (dry basis) when reforming is carried out with a water/model compound mixture similar to that experimentally used. Only H
2, CO
2, CO and CH
4 are present in the gas phase. No formation of molecules with two or more carbons (C
2+) was predicted although side reactions may occur, since the energy of those molecules is generally higher than the energy of the final state, which is highly unstable under steam reforming conditions. Therefore, C
2+ hydrocarbons are intermediate products in the reaction scheme which are absent in the reaction product stream at equilibrium conditions. This coincides with previous studies [
51,
52,
53].
According to this, from the thermodynamics point of view, the steam reforming of the bio-oil aqueous fraction compounds can be represented by a combination of the following equations:
Regarding the evolution of products with temperature, in all cases, the hydrogen content in the outlet stream increases with temperature, as the methane content decreases, to reach a maximum. This is caused by steam reforming (Equation (2)) being favored as temperature increases, because this is an endothermal reaction while methanation reactions (Equations (4) and (5)) are unfavored, as they are highly exothermal. Since water-gas shift (Equation (3)) is an exothermal reaction, the CO mol % increases at the expense of CO2 as the temperature increases, consuming also H2 (reverse reaction). This leads to the decrease of the H2 content above a temperature at which methanation is almost completely unflavoured (CH4 content below 0.2 mol %).
The maximum H
2 production at equilibrium, as well as the temperature at which it is reached, depends on the compound fed to reforming and the steam/carbon ratio (S/C). The highest H
2 content in the product stream (69.2 mol %) is reached by phenol steam reforming at 565 °C. According to the stoichiometry of the global reforming reaction of each of the compounds (Equations (6)–(9)), 70 mol % H
2 could be reached by phenol and hydroxyacetone SR, while 66.7 mol % H
2 would be expected for acetic acid and furfural SR.
The fact that lower H2 content is achieved with hydroxyacetone than phenol or even furfural is due to the lower S/C fed to the reactor, which limits steam reforming and water–gas shift reactions and favors methanation. In addition, temperature at which maximum H2 production takes place is in the range 550–700 °C, the lowest temperature corresponding to phenol and furfural SR due to the high S/C. On the basis of these results, a temperature of 600 °C was selected to perform the catalytic tests using the Ni-M/SBA-15 catalysts. The same temperature was used for both the steam reforming of model compounds and the simulated bio-oil aqueous phase in order to extract valuable conclusions regarding the interaction between the different reactants in the mixture.
2.2.2. Steam Reforming of Model Compounds on Ni-M/SBA-15 Catalysts
The results obtained in the steam reforming of the different model compounds using the prepared catalysts are shown in
Figure 3 and
Figure 4, in terms of conversion and product distribution in the gas stream, respectively. In all cases, the tested catalysts kept conversions above 95 % under the present operation conditions, except for the Ni-Cu/SBA-15 sample, which clearly suffers from deactivation. In general, conversions were higher in the steam reforming of acetic acid (AA) and furfural (Fur), while the steam reforming of hydroxyacetone (HA) led to lower conversion, coinciding with the highest loss of activity of the Ni-Cu/SBA-15 sample. Ni-Co/SBA-15 and Ni-Cr/SBA-15 were the most active samples. This may be ascribed to the smaller Ni crystallites’ size, especially in the Ni-Cr/SBA-15 sample (see
Table 1), and the presence of Co, which is known for its reforming activity [
11], in the Ni-Co/SBA-15 catalyst. Comparing feedstocks with similar S/C ratio, in order to exclude the positive effect of water excess, AA (S/C = 4) is more easily reformed than HA (S/C = 2.67) while furfural (S/C = 13.2) is easier to convert than phenol (S/C = 11). This indicates a decrease in reactivity with increasing carbon number, in agreement with Trane-Restrup et al. [
54]. Although the C–C bonds in aromatic compounds (Fur and Ph) are more stable than in AA or HA, which may result in lower reactivity [
21], the higher S/C ratio used with those promoted higher conversion.
The main products obtained in the gas stream were H
2, CO
2, CO and CH
4 (
Figure 4). Only acetone could be detected as an intermediate in the condensate stream of AA and HA steam reforming but with concentrations lower than 0.1 wt % and 0.7 wt %, respectively. This intermediate could be formed by ketonization of acetic acid or hydrodeoxygenation of hydroxyacetone, but its low concentration indicates that it was almost fully converted to hydrogen and carbon oxides, because as predicted by thermodynamics (
Section 2.2.1), it should be highly unstable under our reaction conditions.
In the case of AA steam reforming, the hydrogen content in the gas stream ranges between 55 (Ni-Cu/SBA-15) and 60 mol % (Ni/SBA-15, Ni-Co/SBA-15 and Ni-Cr/SBA-15), relatively close to the equilibrium value, 63.9 mol %. CH
4 formation is low (<1.8 mol %), but slightly higher than the equilibrium value, while CO and CO
2 are the main C
1 products with CO
2/CO ratios below equilibrium. This may indicate that both CH
4 and CO are intermediates in the AA steam reforming pathway, while CO
2 should be a final product. This can be explained by decomposition (Equation (10)) or decarboxylation (Equation (11)) of AA, followed by methane steam reforming (Equation (12)) and water–gas shift (Equation (5)), taking place in a more complex pathway than the general one proposed from the thermodynamic analysis (Equations (2)–(5)), where CH
4 was formed from the products of steam reforming through methanation reaction unfavored at high temperatures.
Decarboxylation and decomposition are side reactions based on a mechanism of dissociative adsorption of AA on the catalyst to form acetate (CH
3COO*) and/or acyl (CH
3CO*) species, which decompose to lead to the formation of methyl species (CH
3*;
x ≤ 3) with release of CO
2 and CO, respectively. Depending on the reaction conditions (temperature, S/C ratio, H
2 concentration, etc.) and the catalyst surface, the methyl species can either be hydrogenated to CH
4 or cleave off further H atoms (CH
3* → CH
x*;
x < 3) [
55,
56]. The remaining carbon would react with hydroxyl groups from the dissociative adsorption H
2O on the catalyst, forming H
2 and CO; otherwise, carbon deposition would occur. According to our results, only a small fraction of methyl species is hydrogenated to CH
4 under the present conditions. Instead, steam reforming reactions are favored on the Ni/SBA-15-based catalysts at 600 °C and S/C ratio = 4.
The CO
2/CO ratio lower than equilibrium would confirm that CO is the primary product of steam reforming reactions, further being converted into CO
2 by water–gas shift. While the rest of samples achieved CO
2/CO ratios higher than 4.0, the less active Ni-Cu/SBA-15 sample led to a CO
2/CO ratio lower than 3.4. In addition, for this catalyst, a trace amount of acetone (less than 0.1 wt %) was detected in the liquid outlet stream, indicating that ketonization of acetic acid (Equation (13)) also occurred during the steam reforming process. Acetone can further undergo steam reforming (Equation (14)) or, on the contrary, it can polymerize by aldol condensation to form coke deposits (Equation (15)). Although dehydration to ketene (Equation (16)) has also been described to occur during AA steam reforming, no evidence of such reaction was observed in this work, which may be ascribed to the low acidity of these catalysts, since dehydration is usually favored on acidic materials [
57]. The absence of ketene in the gas phase products implies that ketene is a surface intermediate readily reacting further [
55], probably through steam reforming (Equation (17)).
Since ketonization and decomposition reactions occur in parallel with the steam reforming, the hydrogen production is lower for the Ni-Cu/SBA-15 catalyst, which shows poorer activity for AA steam reforming. The rest of samples reached similar hydrogen production.
Similar results were obtained in the HA steam reforming, with hydrogen contents in the gas stream between 52 (Ni-Cu/SBA-15) and 61 mol % (Ni/SBA-15, Ni-Co/SBA-15 and Ni-Cr/SBA-15), the equilibrium value being 64.0 mol %. CO and CO
2 are the main C
1 products with CO
2/CO ratios below half the equilibrium value. On the other hand, contrary to the case of AA, the CH
4 content in the gas phase is slightly lower than equilibrium prediction, except for the Ni-Cu/SBA-15 sample. Again, it can be explained by a reaction network more complex than that extracted from the thermodynamic analysis (Equations (2)–(5)). Methane can be formed by HA decomposition (Equation (18)), maybe occurring in several steps implying some intermediates. Since acetone was detected in the condensate phase, the hydrodeoxygenation of HA (Equation (19)) should be taking place in parallel to steam reforming, and acetone decomposition (Equation (20)) would lead to CH
4 formation. Although it is accompanied by ketene formation, the fact that ketene was not detected among the products may be explained by its high reactivity, probably through steam reforming according to (Equation (17)).
According to Wang et al. [
56], the decomposition mechanism of HA starts with the formation of CH
3COCH
2O* or CH
3COCH
2* species. The latter could form acetone by hydrogenation [
58]. However, the most likely reaction pathway involves the CH
3COCH
2O* species, further decomposing to methyl species (CH
3*) through several steps implying acyl (CH
3CO*) species, similarly to AA decomposition but with no expected CO
2 release. Catalyst and operating conditions would determine CH
4 formation by CH
3* hydrogenation or H
2 and CO generation by cleavage of C–H bonds of CH
3* and interaction of the remaining carbon precursor with OH* or O* intermediates formed from H
2O decomposition. In this case, the low CH
4 content among the gas products and the high carbon oxides formation indicate that these Ni/SBA-15-based catalysts favored steam reforming reactions over decomposition of HA under the present operating conditions. However, poorer activity of Ni-Cu/SBA-15 sample, as shown in
Figure 3b, led to higher CH
4 formation, lower CO
2/CO ratio and, consequently, lower H
2 production than the rest of samples.
Finally, in the steam reforming of Fur and Ph, only H
2, CO
2 and CO were detected as reaction products. The absence of CH
4 in the products stream is ascribed to the high S/C ratio and the fact that there is no CH
3 group in the structure of Fur and Ph [
59]. This implies that CO
x formation by steam reforming of CH* or C* species formed from the decomposition of the Fur or Ph ring [
60] is more favored than the hydrogenation of those intermediate species to CH
4 in these reaction conditions. In addition, although methanation could take place according to the reactions scheme suggested for the equilibrium calculations (Equations (4) and (5)), this reaction is disfavored at 600 °C due to its exothermicity. Regarding hydrogen production, the equilibrium concentration is nearly reached in both Fur and Ph steam reforming. The slight differences in hydrogen formation are in line with the CO
2/CO ratio, so that the higher the ratio the higher the hydrogen content among the products. Contrary to the previous feedstocks, despite the lower conversion of the Ni-Cu/SBA-15 catalysts in the Fur and Ph steam reforming (
Figure 3), the hydrogen content is also near the equilibrium prediction. This is probably a consequence of the favorable reaction conditions derived from the high S/C ratio used with these reactants as a consequence of their low solubility.
2.2.3. Coke Formation during the Steam Reforming of Model Compounds on Ni-M/SBA-15 Catalysts
All the used catalysts were analyzed by thermogravimetric analyses (TGA) in order to determine coke deposition and coking rates summarized in
Table 2. Independently of the model compound fed in the steam reforming test, the coking rate varies in the order: Ni-Cu/SBA-15 > Ni/SBA-15 > Ni-Co/SBA-15 > Ni-Cr/SBA-15.
It is noticeable that the coking resistance of Ni-Cr/SBA-15 decreases by 2 (Ph) to 13 (AA) times the amount of coke formed over our reference material Ni/SBA-15. This is mainly attributed to the small Ni crystallites in this sample which avoid the formation of the intermediary surface species of coke deposition [
30]. The presence of Co, which is less prone to coke accumulation than Ni [
11], would explain the also high coking resistance of the Ni-Co/SBA-15 sample. On the contrary, enhancement of the carbon formation mechanism has been reported at certain Cu loadings in Cu-Ni catalysts [
61], which accounts for the Ni-Cu/SBA-15 sample leading to the highest coke deposition. This sample also showed a decrease of conversion relative to time-on-stream (see
Figure 3), which would indicate a relationship between the amount of coke formed and deactivation. Since this effect was more noticeable in the HA steam reforming, the corresponding derivative thermograms are shown in
Figure 5. All the samples show a wide Derivative Thermogravimetry (DTG) profile between 450 and 625 °C with maximum carbonaceous matter combustion rate taking place between 536 and 565 °C (T
max). These temperatures are in accordance with the combustion of filamentous coke typically formed over Ni catalysts during steam reforming [
29,
30] and the wide profile indicates the presence of carbonaceous species with different ordering degree. Concretely, in the case of Ni/SBA-15 and Ni-Cu/SBA-15 samples, two regions can be distinguished. Peaks at lower temperature correspond to less ordered carbon while those at 565 °C indicate higher graphitization degree of the carbon species. The characteristics of the coke deposited in steam reforming is a result of a balance between its formation and its elimination by gasification, which depends on the operating conditions, time-on-stream and the catalyst employed [
62]. As coke is formed, it evolves from amorphous towards filamentous coke, which progressively undergoes condensation, increasing its ordering degree and finally leading to graphitic coke [
63], which has been described as the cause of deactivation by blocking the Ni particles. Thus, the peak at lower temperature in the DTG profile of Ni-Cu/SBA-15 may be ascribed to incipient structures of filamentous coke, still present as a consequence of the high carbon formation rate of this catalyst, while the peak at 565 °C may be ascribed to aged filaments in the form of a more graphitic coke, which burns at higher temperature. The presence of this aged coke is the cause for the loss of conversion with time of Ni-Cu/SBA-15 sample. Similarly, the peak of this more graphitic coke can be observed in the profile of Ni/SBA-15 sample, but in lower proportion, which would account for the slight deactivation observed in this catalyst.
Regarding carbon deposition from different feedstocks,
Table 2 shows that the coking rate varies in the order: HA > AA > Fur > Ph. It has been stated that carbon formation in steam reforming is largest for olefins and aromatics and also larger for large molecules compared with smaller ones [
13]. However, coke deposition depends on the S/C ratio since higher steam content in the feed should favour gasification of carbonaceous material. Given the significantly higher S/C ratio used with in Ph and Fur, the higher coking rate in HA and AA steam reforming can be explained. It is interesting to note that, although the lowest coke amount was formed with Ph, deactivation was more severe than that of steam reforming of Fur or even AA. Thus, the nature of coke should depend on the feedstock.
Figure 6 shows the derivative thermograms of the used Ni-Cu/SBA-15 sample. The maximum carbon oxidation temperatures (T
max) correspond to filamentous coke in all cases, but different peaks corresponding to various ordering degrees can be observed depending on the steam reforming feedstock. The peak assigned to a more graphitic coke is the only one that can be observed (T
max = 569 °C) in the Ph steam reforming, while the peak assigned to a poorly evolved coke (T
max = 528 °C) is predominant in the Fur steam reforming. This could be related with the loss of activity observed with Ph as opposed to Fur steam reforming.