Catalyst Coatings for Ammonia Decomposition in Microchannels at High Temperature and Elevated Pressure for Use in Decentralized and Mobile Hydrogen Generation

We report an investigation of catalyst performance for the decomposition of ammonia under industrially relevant conditions (high temperatures of up to 800 °C and an elevated pressure of 5 bar) with further emphasis on their stability at high reaction temperatures. The catalysts were applied and tested as coatings in 500 µm wide channels of microreactors. Nickel-based catalysts were studied and compared to a ruthenium-based catalyst supported on SiO2. The effect of the support on the catalytic performance was investigated, and CeO2-supported nickel catalysts were found to exhibit the highest activity. Promoters were applied to increase the NH3 decomposition activity of the Ni/CeO2 catalysts. The addition of cesium led to a slight reduction in activity, while lanthanum, calcium, and barium doping resulted in increased activity. In particular, the barium-doped Ni/CeO2 catalyst showed very high ammonia conversion and closed the activity gap with respect to ruthenium catalysts at reactor temperatures of 650 °C and higher. The hydrogen production rates achieved in this work were compared to values in the literature and were shown to exceed values found earlier for both nickel- and ruthenium-based catalysts. Furthermore, the ruthenium-based catalysts under investigation were rapidly deactivated at 700 °C, while the nickel-based catalysts did not show deactivation after 220 h on time on stream at 700 °C.