JPS5524193 | MANUFACTURE OF METHANONAPHTHALENE |
JPS5527173 | HYDROCARBON SYNTHESIS |
YAO XUELI (SA)
BAI XUEQIN (SA)
KWON OHHUN ET AL: "Self-assembled alloy nanoparticles in a layered double perovskite as a fuel oxidation catalyst for solid oxide fuel cells", JOURNAL OF MATERIALS CHEMISTRY A, vol. 6, no. 33, 1 January 2018 (2018-01-01), GB, pages 15947 - 15953, XP093049966, ISSN: 2050-7488, DOI: 10.1039/C8TA05105D
WHAT IS CLAIMED IS: 1. A catalyst comprising: a double-layer perovskite support; and nanoparticles including nickel and one or more transition metals, wherein the nanoparticles are in contact with the double-layer perovskite support. 2. The catalyst according to claim 1, wherein the double-layer perovskite support includes praseodymium, barium, and manganese. 3. The catalyst according to any one of claims 1-2, wherein the one or more transition metals are selected from iron, cobalt, copper, and molybdenum. 4. The catalyst according to any one of claims 1-3, wherein the nanoparticles include iron and the double-layer perovskite support is in the tetragonal phase. 5. The catalyst according to any one of claims 1-4, wherein the nanoparticles include a Ni3Fe1 alloy. 6. The catalyst according to any one of claims 1-5, wherein the diameter of the nanoparticles ranges from 10 nm to 40 nm. 7. The catalyst according to any one of claims 1-6, wherein the nanoparticles are substantially spherical and are anchored into the double-layer perovskite support, and wherein greater than 90% of the total Ni is in the metallic state. 8. The catalyst according to any one of claims 1-7, wherein the catalyst includes the following formula: PrBaMn1.6Ni2(0.2-X)FeXO5+δ, wherein X ranges from 0 to 0.2. 9. The catalyst according to any one of claims 1-8, wherein the catalyst includes the product of one or more of exsolving the nanoparticles and reducing a single perovskite support. 10. A method of processing a feed stock, the method comprising: contacting the feed stock with a catalyst, sufficient to generate a reaction product, wherein the catalyst includes: a double-layer perovskite support; and nanoparticles including nickel and one or more transition metals, wherein the nanoparticles are in contact with the double-layer perovskite support. 11. The method according to claim 10, wherein the feed stock includes one or more of carbon dioxide, methane, water, and hydrogen and the reaction product includes one or more of hydrogen, water, and carbon monoxide. 12. The method according to any one of claims 10-11, including a reaction selected from dry reforming of methane (DRM), steam reforming of methane (SRM), catalytic decomposition of methane (CDM), and electrochemistry including solid oxide fuel cell (SOFC). 13. The method according to any one of claims 10-12, wherein the one or more transition metals are selected from iron, cobalt, copper, and molybdenum and the double-layer perovskite support is in the tetragonal phase. 14. The method according to any one of claims 10-13, wherein the catalyst includes the following formula: PrBaMn1.6Ni2(0.2-X)FeXO5+δ, wherein X ranges from 0 to 0.2. 15. A method of making a catalyst, the method comprising: contacting praseodymium salt, barium salt, manganese salt, nickel salt, and a transition metal salt with one or more complexation agents sufficient to form a solution; heating the solution sufficient to form a gel; heating the gel sufficient to separate a solid; and calcining the solid. 16. The method according to claim 15, wherein the complexation agent includes one or more of citric acid and ethylene glycol. 17. The method according to any one of claims 15-16, wherein heating the gel includes heating at a temperature greater than 300 °C and calcining includes heating the solid at a temperature greater than 700 °C. 18. The method according to any one of claims 15-17 further comprising reducing the catalyst in gas at a temperature above 500 °C. 19. The method according to any one of claims 15-18, wherein the catalyst includes Ni3Fe1 alloy nanoparticles. 20. The method according to any one of claims 15-19, wherein the catalyst includes a double-layer perovskite support in the tetragonal phase. |
Table 1. Chemical Compositions and abbreviations of samples. Table 2. Nominal and actual loading wt.% of catalysts. [0070] FIG. 3A illustrates crystalline structures of the parent PrBaMn 2 O 5+δ (P) and the corresponding exsolved counterparts P-Ni 0.2-x Fe x (x = 0, 0.05, 0.1, 0.2) with different Ni/Fe loading analyzed using x-ray diffraction (XRD), according to some embodiments. FIG. 3A shows the results after sintering at 950 °C for 4 h in air. The parent and exsolved materials include a perovskite structure with a mixture of hexagonal and cubic phases with no detectable impurity phases. FIG. 3B illustrates crystalline structures of the parent PrBaMn 2 O 5+δ (P) and P-Ni 0.2-x Fe x (x = 0, 0.05, 0.1, 0.2) after reduction, according to some embodiments. Reduction was completed at 800 °C in 10% H 2 /Ar for 6 h. The reduction induced the transformation of the original perovskite into a layered perovskite in the tetragonal phase, which can increase the specific surface area due to the formation of metal (Ni or Ni-Fe alloy) nanoparticles on the support surface and defects in the lattice. [0071] FIG. 3C illustrates a closeup schematic of FIG. 3B showing the crystalline structures of the parent PrBaMn 2 O 5+δ (P) and P-Ni 0.2-x Fe x (x = 0, 0.05, 0.1, 0.2) after reduction, according to some embodiments. The exsolution of a metallic Ni phase was verified by the appearance of the crystal planes (111) with a d-spacing of 2.030 Å for P-Ni 0.2 . Concerning P- Ni 0.15 Fe 0.05 , the d-spacing of the exsolved metal phase increases to 2.037 Å, assigned to the (111) crystalline planes of the Ni-Fe alloy, deriving from Fe dissolving into the Ni lattice, revealing that the exsolved metal forms a binary Ni-Fe alloy. Upon reduction, the exsolved nanoparticles in B sites are MnO for P, metallic Ni for P-Ni 0.2 , and Ni-Fe alloy for P-Ni 0.15 Fe 0.05 and P‑Ni 0.1 Fe 0.1 , whereas no exsolved Fe phase is evident for P-Fe 0.2 . The same trend of transition metal exsolution in the layered perovskite was previously observed, indicating that Ni exsolves more efficiently to the surface than Mn and Fe. The results demonstrate that, although Fe alone hardly exsolves, it does so primarily with Ni, forming a Ni-Fe alloy nanoparticle. [0072] FIG.3D illustrates scanning electron microscopy (SEM) of pristine P-Ni 0.15 Fe 0.05 , according to some embodiments. FIG.3E illustrates scanning electron microscopy of exsolved (E)-Ni 0.15 Fe 0.05 , according to some embodiments. FIG. 3F illustrates transmission electron microscopy (TEM) of exsolved E-Ni 0.15 Fe 0.05 , according to some embodiments. The exsolution of the nanoparticles was observed from the morphology of the P-Ni 0.15 Fe 0.05 material. The pristine P-Ni 0.15 Fe 0.05 material is relatively smooth, whereas numerous nanoparticles emerged on the surface after H 2 treatment (FIG. 3E), and the exsolved nanoparticle was partially socketed in the support (FIG.3F). [0073] FIG.3G illustrates high-angle annular dark-field scanning TEM (STEM) imaging and elemental mappings computed from STEM-energy dispersive x-ray spectroscopy data for the E-Ni 0.15 Fe 0.05 catalyst after H 2 -reduction, according to some embodiments. FIG. 3G indicates the spherical shape of the Ni-Fe particles anchored to the surface of the double-layer perovskite. The interplanar spacing of the nanoparticles is 2.05 Å, which is consistent with the d‑spacing of the (111) plane of the Ni-Fe alloy phase. The particle size analysis of the E- Ni 0.15 Fe 0.05 catalyst indicates an average of 21 ± 5.6 nm. The EDS elemental mappings highlight that only Ni and Fe atoms were found in the emergent nanoparticles. The quantitative analysis of the EDS data operated on more than 30 nanoparticles indicated a molar Ni/Fe ratio of 3.6 ± 1.0. The chemical elements Pr, Ba, Mn, and O are homogeneously distributed across the support. Only traces of Ni atoms remained in the perovskite, whereas a substantial number of Fe atoms were still present. The same exsolution phenomenon of Ni nanoparticles was also observed for E-Ni 0.2 . [0074] FIG. 4A illustrates normalized Ni K-edge x-ray absorption near-edge structure (XANES) spectra of various catalysts, according to some embodiments. In the normalized Ni K-edge x-ray absorption near-edge structure (XANES) spectra, the Ni K-edge spectra almost fit with the Ni foil reference concerning the energy position and pattern, indicating that Ni is prevailingly reduced to Ni 0 in the two catalysts. In addition, the pre-edge peak slightly shifts to higher energy from E-Ni 0.2 to ENi 0.15 Fe 0.05 (enlarged region in FIG. 4A), demonstrating the minor increase in the Ni average oxidation state. [0075] FIG. 4B illustrates normalized Fe K-edge x-ray absorption near-edge structure spectra of various catalysts, according to some embodiments. Moreover, the white line (7131 eV) of the Fe K-edge XANES spectrum of the E-Ni 0.15 Fe 0.05 catalyst is more intense than that of Fe foil in FIG. 4B, indicating that part of the Fe is oxidized. The intensity of the pre-edge peak of E-Ni 0.15 Fe 0.05 is stronger than that of the Fe 2 O 3 reference. Thus, it is deduced that part of the Fe is reduced to metallic Fe 0 , whereas another part remains oxidized in the double-layer perovskite support. [0076] FIG. 4C illustrates corresponding k3-weighted Ni K-edge extended XAFS (EXAFS) spectra in k spaces, according to some embodiments. FIG. 4D illustrates Fourier transform of k3-weighted Ni K-edge EXAFS for E-Ni 0.15 Fe 0.05 and E-Ni 0.2 , according to some embodiments. The monometallic E-Ni 0.2 reveals the same oscillations as those of the Ni foil, whereas in terms of the bimetallic E-Ni 0.15 Fe 0.05 , the changes minorly shift to a smaller k-value. The EXAFS spectra of both E-Ni 0.2 and E‑Ni 0.15 Fe 0.05 have features similar to the Ni foil, with the majority of Ni-Ni coordination at ∼2.18 Å and a minority of Ni-O coordination (FIG.4D). The wavelet transform signals of the Ni-metal bond were observed around 8 Å −1 in the contour plots of the E-Ni 0.15 Fe 0.05 , E-Ni 0.2 , NiO reference, and Ni foil. In contrast, the Ni-O bond signals were absent except for the NiO standard. This result confirms that most Ni exists in the metallic state. [0077] FIG. 4E illustrates Ni K-edge with linear combination fitting of E-Ni 0.15 Fe 0.05 , according to some embodiments. The linear combination fitting method was adopted based on the identifiable features of each reference in the XANES spectra to quantify the distribution of different Ni and Fe oxidation states. The linear combination fitting analysis of the Ni K-edge XANES spectrum reveals that about 94.0% of Ni is reduced to the metallic state, which is almost double the results for conventional catalysts (58% Ni exsolved), and only 6.0% of Ni remains in the oxidation state in E-Ni 0.15 Fe 0.05 . [0078] FIG. 4F illustrates Fe K-edge with linear combination fitting of E-Ni 0.15 Fe 0.05 , according to some embodiments. The distribution of Fe in E‑Ni 0.15 Fe 0.05 is approximately 25.1% Fe 0 and 74.9% in the Fe oxidation state. FIG.4G illustrates a wavelet transform EXAFS plot of Ni foil, according to some embodiments. FIG. 4H illustrates a wavelet transform EXAFS plot of NiO, according to some embodiments. FIG. 4I illustrates a wavelet transform EXAFS plot of E-Ni 0.15 Fe 0.05 , according to some embodiments. FIGS.4G-4I confirm that most Ni exists in the metallic state. It is inferred that Fe was partially reduced to the metallic phase and exsolved to the surface of the perovskite matrix, forming an alloy with Ni. [0079] The catalytic activity and stability of the preceding impregnated (I-) and exsolved (E-) catalysts were further evaluated in dry reforming at 800 °C at atmospheric pressure and high pressure (14 bar), respectively. Catalytic tests were performed in a four-channel reactor The reactors are 300-mm-long quartz tubes, of which the outside and inside diameters are 3 and 2 mm, respectively. One of the reactors was adopted as the blank without a loading catalyst among the four channels. The proper amount of catalyst and reactant mixture gas flow was used to maintain the gas hourly space velocity (GHSV) per channel at 30,000 mL g cat –1 h –1 under atmospheric pressure and 12,000 mL g cat –1 h –1 under high pressure at 14 bar, respectively. The composition of the reactant mixture gas was CH 4 :CO 2 :N 2 = 33%:34%:33%. Before the test, the catalysts were reduced in situ in a 10% H 2 /Ar atmosphere for 6 h at 800°C. [0080] FIG.5 illustrates DRM activity of various catalysts after a 12 h test, according to some embodiments. FIG. 5 corresponds to the following reaction conditions: T = 800 °C, CH 4 /CO 2 /N 2 = 33/34/33, and GHSV = 30,000 mL g cat –1 h –1 . The initial reaction rate of both CH 4 and CO 2 is much higher for exsolved catalysts (E‑Ni x , x = 0.1, 0.2, and 0.3) than for their impregnated counterparts (I-Nix). However, the deactivation is much faster in the impregnated catalysts than the exsolved counterparts at an 11.5% drop within 12 h on stream for the I-Ni 0.2 catalysts. The E-Nix catalysts remain stable for the CH 4 and CO 2 reaction rate throughout 40 h on stream, mirroring the same stability as the H 2 /CO ratio. As for the effect of the Ni loading, the reaction rate decreased as the amount of Ni increases, in spite of the conversion delivered opposite trend, which is probably caused by the incomplete exsolution of the Ni active site. [0081] Based on the aforementioned results, E-Ni 0.2 is further modified with the dopant of Fe in the B site (E-Ni 0.2-x Fe x (x = 0.05, 0.1, 0.2)). The CH 4 reaction rate of the E-Ni 0.15 Fe 0.05 catalyst is slightly lower than that of the E-Ni 0.2 (FIG. 5). The CH 4 reaction rate of the ENi 0.1 Fe 0.1 catalyst is not stable during 40 h on stream. Moreover, the CH 4 reaction rate of E- Fe0.2 is null, indicating that the perovskite substrate and Fe nanoparticles are both inert in the conversions of CH 4 and CO 2 . The reaction rate of CO 2 is faster than that of CH 4 for all catalysts, independent of the metal loading and its nature. This phenomenon is highlighted in the Ni-Fe alloy catalyst because Fe is an active site for the reverse water-gas shift reaction. [0082] FIG. 6A illustrates DRM performance of E-Ni 0.2 and E-Ni 0.15 Fe 0.05 for a continuous catalytic reaction, according to some embodiments. The reaction conditions are as follows: T = 800 °C, CH 4 /CO 2 /N 2 = 33/34/33, GHSV = 30,000 mL g cat –1 h –1 . After around 135 h on stream, the stability test of E-Ni 0.2 ceases because the catalyst bed is congested with coke (the pressure drop rises and the flow rate decreases). The E-Ni 0.15 Fe 0.05 catalyst displays a stable reaction rate with no noticeable deactivation for 260 h on stream at 800°C. This result indicates that Fe plays a critical role in stabilizing the catalyst. Industrial syngas must be compressed, such as compression from 1 to 10 bars, for utilization, which costs more than 85% of the total capital investment and 60% of the operational costs. Additionally, high-pressure operation also increases the production capacity. [0083] FIG. 6B illustrates DRM performance of E-Ni 0.2 and E-Ni 0.15 Fe 0.05 for a continuous catalytic reaction at 14 bar, according to some embodiments. The reaction conditions are the following: T = 800 °C, CH 4 /CO 2 /N 2 = 20/60/20, GHSV = 12,000 mL g cat –1 h -1 . Coking is highly thermodynamically favored at high-pressure operation conditions, which is the central dilemma to address. Both E-Ni 0.15 Fe 0.05 and E-Ni 0.2 exhibit 40 h stability in reaction conditions at 14 bar. Compared to some conventional catalysts, E-Ni 0.15 Fe 0.05 exhibits similar CH 4 conversion, lower CO 2 conversion, and a much higher H 2 /CO ratio, even without 10% H 2 O feeding, indicating that E-Ni 0.15 Fe 0.05 is also a promising catalyst for the high- pressure dry reforming of CH 4 . [0084] To elucidate the role of Fe on the carbon resistance of Ni-based catalysts under reaction conditions, thermogravimetric techniques were applied to measure the carbon deposition on the used catalyst. The CO 2 signal was analyzed in a mass spectrometer during combustion. FIG. 6C illustrates thermogravimetric analysis of used E-Ni 0.2 (135 h) and E- Ni 0.15 Fe 0.05 (260 h) catalysts after different times, according to some embodiments. The analysis was completed at 800 °C in 10% O 2 /Ar. As depicted in FIG.6C, the coke formation rate on the E-Ni 0.2 catalyst is 2.57 E-5 mmol g cat alyst −1 s −1 during the 135 h on stream, whereas the coke formation rate significantly drops to 4.71 E-8 mmol g catalyst −1 s −1 for the E-Ni 0.15 Fe 0.05 catalyst during the 260 h on stream. [0085] FIG. 6D illustrates a particle size distribution histogram for E-Ni 0.15 Fe 0.05 and I- Ni 0.2 catalysts after reduction and DRM with different times on stream, according to some embodiments. As shown, the average particle size of the exsolved catalyst increased much less than the wetness impregnation catalyst. The particle size distribution analysis revealed that the used E-Ni 0.15 Fe 0.05 catalyst possessed exsolved Ni-Fe nanoparticles with an average size of 30.1 nm after 260 h on stream, slightly larger than the nanoparticles of the E-Ni 0.15 Fe 0.05 before the reaction (21.0 nm). The exsolved nanoparticles of the used E-Ni 0.15 Fe 0.05 catalyst are still partially anchored in the support without any observable C with a morphology similar to the pristine one. However, the counterpart used I-Ni 0.2 catalyst exhibited severe sintering of Ni particles from 35.2 to 56.6 nm, only after 12 h on stream with apparent filament C on the catalyst surface. In addition, elemental mappings focused on Ni-Fe nanoparticles of E- Ni 0.15 Fe 0.05 depicted identical features before and after the reaction: a homogenous distribution of Ni and Fe through the particles without noticeable metal segregation. Hence, the exsolved E-Ni 0.15 Fe 0.05 catalyst exhibited improved sintering resistance compared with the I-Ni 0.2 catalyst, which is closely associated with their stability (FIG.6A). [0086] FIG.7 illustrates a comparison of the present catalysts to conventional catalysts, according to some embodiments. Compared with approximately 140 conventional catalysts, the proposed ENi 0.15 Fe 0.05 catalyst has the slowest coke formation rates of the relatively extensive catalyst portfolio. Many studies do not assess coke fouling on the catalysts for the following reasons: (i) insufficient time on stream, (ii) unrealistically mild reaction conditions, or (iii) inappropriate excess of catalyst and the subsequent underestimation of coke formation. Per the thermogravimetric results, contrary to the severe coking on the used E-Ni 0.2 catalyst, the Raman spectra indicated no coke accumulation on the used E-Ni 0.15 Fe 0.05 catalyst. The minor coking deposition convincingly demonstrates the coking-resistant effect of Fe, coinciding with previous reports that Fe substitution improves the C resistance of Ni-based catalysts in reaction conditions. [0087] The DFT calculations were performed to compare the adsorption energy of the key intermediates on Ni 4 Fe 1 (111) models to that on monometallic Ni (111) models to elucidate the improved coking resistance of the Ni-Fe bimetallic catalyst. These surfaces were identified experimentally using high-resolution TEM. The support in the E-Ni 0.2 and E-Ni 0.15 Fe 0.05 catalysts was perovskite, which is almost inert to the main reactions (in FIG. 5, E-Fe0.2 has negligible activity); thus, only the monometallic Ni and bimetallic Ni-Fe alloy were considered for the slab model. [0088] The binding energies of the critical intermediates on Ni 4 Fe 1 (111) were compared with those on Ni (111), as presented in Table 3. Despite the same binding energy of CH 4 between Ni (111) and Ni 4 Fe 1 (111), the binding strength of C-containing intermediates, including CH3*, CH 2 *, CH*, C*, and CO*, are all weaker on the Ni 4 Fe 1 (111) surface than on the Ni (111) surface, on which coke is likely prone to form due to the higher C* binding energy. In addition, due to the stronger Fe-O bond, the adsorption of the oxygen-containing species, such as O* and CHO*, on the Ni 4 Fe 1 (111) surface are stronger than that on the Ni (111) surface. The O* and CHO* adsorption strengths are 0.15 and 0.08 eV higher than the pure Ni (111) surface. Table 3. Comparison of energy barriers of elementary reactions involved in DRM. [0089] FIG. 8A illustrates potential energy profiles for the C atom and CH oxidation pathways on Ni (111) and Ni 4 Fe 1 (111) surfaces, respectively, according to some embodiments. FIG.8B illustrates geometries of transition states for CH dehydrogenation and C oxidation (C oxidation pathway), according to some embodiments. FIG. 8C illustrates CH oxidation and CHO dissociation (CH oxidation pathway), according to some embodiments. The C formation is determined by the surface C* concentration, which is considered the precursor to C formation. The surface C* primarily originates from CH* and CO* dissociating from CH 4 and CO 2 , respectively. The DFT calculation results indicate that the CO* dissociation is highly unfavored due to much higher energy barriers on both Ni (111) (2.97 eV) and Ni 4 Fe 1 (111) (2.70 eV) surfaces compared with barriers to the CH* dissociation, consequently restraining the C* formation from CO* dissociation (Table 3). The barrier energy for CH* dissociation is 1.10 eV on the Ni (111) surface and 1.03 eV on the Ni 4 Fe 1 (111) surface. Hence, the C* concentration depends on the formation and consumption of C* deriving from the intermediate CH*. [0090] Two pathways, (i) the C and (ii) CH oxidation pathways, should be considered to establish the energy diagram of the reactions from intermediate CH* to the final state of CO* and H* because the CH* results in the competitive formation of C* and CO*. Each pathway includes two steps: CH direct dissociation (CH* → C* + H*) and C oxidation (C*+ O* → CO*) for the C oxidation pathway, and CH oxidation (CH* + O* → CHO*) and CHO dissociation (CHO* → CO* + H*) for the CH oxidation pathway, as illustrated in FIGS. 8A- 8C. The effective barriers were calculated for the two pathways, defined as the difference between the highest-transition and lowest intermediate states in the whole reaction. The effective barriers for the C and CH oxidation pathways are 2.22 and 1.13 eV, respectively, on the Ni 4 Fe 1 (111) surface, indicating that the CH oxidation pathway is much more favorable than the C oxidation pathway. [0091] A similar trend is observed on the Ni (111) surface. However, the energy barrier distinction between the two oxidation pathways strikingly increases from 0.88 eV on Ni (111) to 1.09 eV on Ni 4 Fe 1 (111), revealing the prevailing dominance of the CHO* oxidation pathway on the Ni 4 Fe 1 (111) surface. This outcome significantly alleviates the C* atom coverage on Ni4Fe1 (111) surface because the formed CH* prefers to couple with oxygen to form CHO*, further converting to CO* and H*, rather than directly decomposing into C*. [0092] More CH* species accumulated on the Ni (111) surface due to the relative inferiority of the CHO* oxidation pathway compared to Ni 4 Fe 1 (111), part of which further decomposes to C* and H*, leading to severe coking. Moreover, adding Fe to the Ni-based catalysts facilitates CO 2 activation (exhibiting a slightly inferior CH 4 activation activity for Ni), releasing more O* species as an oxidant to promote C removal, to an extent. Overall, the calculations demonstrate that the prevailing dominance of the CHO* oxidation pathway and the increased available atomic O* species synergistically contribute to the outstanding coking resistance of the Ni-Fe binary alloy catalyst, which is consistent with the experimental results. [0093] Compared with the conventional impregnated catalysts, the exsolved catalysts possess unique anchor effect, which significantly prevents sintering. The exsolved fraction of Ni attained 94%. The CH 4 reaction rate in DRM reached to 1.74 E-03 mol gNi –1 s –1 . More importantly, the E-Ni 0.15 Fe 0.05 catalyst achieved 260 h stability at 800 °C under CH 4 /CO 2 /N 2 =33/34/33 with the coke formation rate of 4.71 E-8 mmol g cat alyst −1 s −1 , which is one of the slowest coke formation rates compared with the conventional catalysts. Further, no deactivation is observed during 40 h operation at high pressure (14 bar). In the Ni 4 Fe 1 binary alloy system, the CHO* oxidation route prevailingly dominates, promoting the oxidation of CH* instead of decomposing to C*, inhibiting the C deposition. Moreover, the weakening binding strength of the C* atom and the enrichment of the oxygen-containing species on the binary alloy Ni 4 Fe 1 (111) surface alleviates the C deposition and facilitates the oxidation of intermediate CHx and surface C, respectively. [0094] Importantly, exsolved Ni nanoparticles on double-layer perovskite are resistant to sintering under harsh dry reforming conditions due to the unique anchoring and metal-support interaction. This catalyst has significantly superior performance and longer stability than the corresponding counterpart catalyst prepared via the wetness impregnation method. The addition of Fe led to the formation of Ni 4 Fe 1 alloy, which exsolves on the double-layer perovskite. This catalyst exhibits robust stability with negligible C deposition during the 260 h on stream. The comprehensive characterization and DFT calculations revealed that, in the Ni- Fe binary alloy system, the CHO* oxidation route prevailingly dominates, promoting the oxidation of CH* instead of decomposing to C*, inhibiting the C deposition. Moreover, the weakening binding strength of the C* atom alleviates the C deposition on the Ni 4 Fe 1 (111) surface. The enrichment of the oxygen-containing species facilitates the oxidation of intermediate CH x and surface C, eliminating coking on the binary alloy Ni 4 Fe 1 (111) surface, thereby significantly boosting the stability of the Ni 4 Fe 1 nanoparticle-decorated double-layer perovskite during the prolonging reaction. Overall, the simultaneous in situ exsolution of the active sites with the second metal promoter to form binary alloy nanoparticle-anchored double- layer perovskite is a low-cost and efficient route to design a highly coking-resistant and robust catalyst for hydrogen production reforming reactions. [0095] The catalyst can be used in the technology which involves the activation of C-H bond in hydrocarbons and their derivatives such as thermal catalysis including DRM, SRM, CDM, and electrochemistry including SOFC. In the application of thermal catalysis, the catalyst possesses outstanding anti-sintering and coking resistant ability so that the catalyst exhibits quite slow coke formation rate and robust stability in the thermal catalysis reactions. In the application of the electrochemistry, the catalyst can be used as electrode which activates the fuel and also conducts the electrons, thus facilitating the anode reaction. For example, in SOFC fueled with hydrocarbon and their derivatives, the catalyst can be utilized as a promising anode which shows high C-H activation, excellent conductivity and carbon resistant ability, so that the SOFC has long stability. Example 2 [0096] A comparison was completed for the DRM performance with conventional catalysts. The results are shown in Table 4 below. Table 4. Comparison of DRM performance. Discussion of Possible Embodiments [0097] According to one aspect, a catalyst includes a double-layer perovskite support and nanoparticles including nickel and one or more transition metals, wherein the nanoparticles are in contact with the double-layer perovskite support. [0098] The catalyst of the preceding paragraph can optionally include, additionally and/or alternatively any one or more of the following features, configurations and/or additional components. [0099] The double-layer perovskite support may include praseodymium, barium, and manganese. [00100] The one or more transition metals may be selected from iron, cobalt, copper, and molybdenum. [00101] The nanoparticles may include iron and the double-layer perovskite support may be in the tetragonal phase. [00102] The nanoparticles may include a Ni 3 Fe 1 alloy. [00103] The diameter of the nanoparticles may range from 10 nm to 40 nm. [00104] The nanoparticles may be substantially spherical and may be anchored into the double-layer perovskite support, and wherein greater than 90% of the total Ni may be in the metallic state. [00105] The catalyst may include the following formula: PrBaMn 1.6 Ni 2(0.2-X) FeXO 5+δ , wherein X ranges from 0 to 0.2. [00106] The catalyst may include the following formula: PrBaMn 1.6 Ni 2(0.2-X) FeX, wherein X ranges from 0 to 0.2. [00107] The catalyst may include the product of one or more of exsolving the nanoparticles and reducing a single perovskite support. [00108] According to one aspect, a method of processing a feed stock includes contacting the feed stock with a catalyst, sufficient to generate a reaction product, wherein the catalyst includes: a double-layer perovskite support and nanoparticles including nickel and one or more transition metals, wherein the nanoparticles are in contact with the double-layer perovskite support. [00109] The method of the preceding paragraph can optionally include, additionally and/or alternatively any one or more of the following features, configurations and/or additional components. [00110] The feed stock may include one or more of carbon dioxide, methane, water, and hydrogen and the reaction product may include one or more of hydrogen, water, and carbon monoxide. [00111] The method may include a reaction selected from dry reforming of methane (DRM), steam reforming of methane (SRM), catalytic decomposition of methane (CDM), and electrochemistry including solid oxide fuel cell (SOFC). [00112] The one or more transition metals may be selected from iron, cobalt, copper, and molybdenum and the double-layer perovskite support may be in the tetragonal phase. [00113] The catalyst may include the following formula: PrBaMn 1.6 Ni 2(0.2-X) FeXO 5+δ , wherein X ranges from 0 to 0.2. [00114] The catalyst may include the following formula: PrBaMn 1.6 Ni 2(0.2-X) FeX, wherein X ranges from 0 to 0.2. [00115] According to one aspect, a method of making a catalyst includes contacting praseodymium salt, barium salt, manganese salt, nickel salt, and a transition metal salt with one or more complexation agents sufficient to form a solution, heating the solution sufficient to form a gel, heating the gel sufficient to separate a solid, and calcining the solid. [00116] The method of the preceding paragraph can optionally include, additionally and/or alternatively any one or more of the following features, configurations and/or additional components. [00117] The complexation agent may include one or more of citric acid and ethylene glycol. [00118] Heating the gel may include heating at a temperature greater than 300 °C and calcining includes heating the solid at a temperature greater than 700 °C. [00119] The method may include reducing the catalyst in gas at a temperature above 500 °C. [00120] The catalyst may include Ni3Fe1 alloy nanoparticles. [00121] The catalyst may include a double-layer perovskite support in the tetragonal phase. [00122] The catalyst may include the following formula: PrBaMn 1.6 Ni 2(0.2-X) Fe X O 5+δ , wherein X ranges from 0 to 0.2. [00123] The catalyst may include the following formula: PrBaMn 1.6 Ni 2(0.2-X) Fe X , wherein X ranges from 0 to 0.2. [00124] While the disclosure has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for elements thereof without departing from the scope of the embodiment(s). In addition, many modifications may be made to adapt a particular situation or material to the teachings of the embodiment(s) without departing from the essential scope thereof. Therefore, it is intended that the disclosure is not limited to the disclosed embodiment(s), but that the disclosure will include all embodiments falling within the scope of the appended claims. Various examples have been described. These and other examples are within the scope of the following claims.
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