Work

Reuse of CO-Oxidation Spent Catalysts for Dry Reforming of Methane: Techno-Economic Analysis

Year: 2026

Type: article

Abstract: High Resolution Image Download MS PowerPoint Slide We report an upcycling route for Pt-based spent CO-oxidation catalysts in stationary plants. By simple Ni impregnation, the spent modules are converted into active dry reforming of methane (DRM) catalysts (oxiCO/Ni). Under DRM at 750 °C, oxiCO/Ni achieves CH 4 and CO 2 conversions >73 and >94%, respectively, with high structural and thermal stability maintained over 7 h of continuous operation. The superior activity and resistance to deactivation are attributed to the formation of the NiAl 2 O 4 spinel phase, strong metal–support interactions, and synergistic effects from residual Pt and La in the spent catalyst. A techno-economic analysis was conducted for a recycling plant capable of processing 205 tons/y of raw spent oxiCO catalyst modules, yielding 16.2 tons/y of oxiCO/Ni catalyst for DRM. The profitability analysis showed that the investment in such a project is profitable with a maximum tipping credit of 6500 US$/ton, giving a net present value of US$ 6.9 million, an internal rate of return of 43%, and a discounted payback time of 4 years and 1 month. This approach couples waste minimization with catalyst circularity, delivering both environmental and economic benefits.

Source: ACS Sustainable Chemistry & Engineering

DOI: 10.1021/acssuschemeng.5c09652

Authors: Ahmed Abotaleb, Nada Abounahia, Alessandro Sinopoli, Francesco Ferella

Institutions: Hamad bin Khalifa University, University of Messina, University of L'Aquila

Language: English

Topic: Catalysts for Methane Reforming

Subfield: Catalysis

Field: Chemical Engineering

Domain: Physical Sciences

SDGs: Responsible consumption and production, Affordable and clean energy, Industry, innovation and infrastructure

Open Access status: hybrid

Estimated APC paid: $4,500