This study focuses on a Pt-promoted Ni/NiAl (Ni/NiO-Al2O3) catalyst for butane steam reforming, designed to overcome hydrothermal oxidation and sulfur poisoning in Ni-based systems. A series of Ni/Al (Ni/Al2O3) and Ni/NiO-Al2O3 catalysts, with and without Pt modification, were synthesized and systematically evaluated under severe reforming conditions. Compared with conventional Ni/Al, Ni/NiAl exhibited stronger metal-support interaction through NiAl2O4 formation but suffered rapid deactivation in steam-rich and sulfur-containing atmospheres. Incorporating 0.5 wt% Pt markedly improved stability, maintaining high activity and hydrogen selectivity during both steam and H2S exposure. Characterization by XRD, TEM, H2-TPR, and XPS revealed that Pt induces a synergistic protection mechanism, in which hydrogen spillover dynamically regenerates oxidized Ni species and weakens Ni
S interactions. This effect reduces sulfur coverage on active Ni sites, preserving highly dispersed metallic Ni0. Time-resolved outlet gas analysis further indicated that sulfur preferentially deactivates reforming sites, followed by progressive inhibition of the water-gas shift reaction via a COS-mediated pathway. The catalyst demonstrated excellent stability under 5 ppm H2S at 850 °C, confirming the dual protective role of Pt against oxidation and sulfur poisoning. These findings provide mechanistic insights and design principles for robust, regenerable Ni-based catalysts tailored for distributed hydrogen production from LPG.
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