Synthesis and optimization of hydrotalcite derived Ni-Fe-Cu based catalysts for catalytic methane decomposition process using the design of experiment approach

Abstract

The optimization of hydrotalcite-derived Ni-Fe-Cu-based tri-metallic catalyst for methane catalytic decomposition has been studied using the Taguchi method. Taguchi L9 orthogonal array consisting of four design factors and one response was considered in the optimization study. The catalysts were thoroughly characterized using various techniques like XRD, BET, H2-TPR, FE-SEM, TGA/DTG, and Raman spectroscopy. The optimization study results revealed that the methane decomposition catalyst's performance and the nature of deposited carbon depend on the catalyst's composition. Both graphitic and carbon nanotubes have been deposited in spent catalysts. The diameter of carbon nanotubes formed over the catalyst depends mainly on the Ni loading. The optimal reaction conditions were found to be 14 wt.% Ni loading, 2 wt.% Fe loading, 2 wt.% Cu loading and 700 °C of calcination temperature. The catalyst performance quality was increased by around 30% at optimal conditions after implementing the Taguchi experiment.