Synthesis, Characterization, and Attrition Resistance of Kaolin and Boehmite Alumina-Reinforced La0.7Sr0.3FeO3 Perovskite Catalysts for Chemical Looping Partial Oxidation of Methane

This study investigates the impact of kaolin and boehmite alumina binders on the synthesis, catalytic properties, and attrition resistance of a La0.7Sr0.3FeO3 (LSF) perovskite catalyst designed for the chemical looping partial oxidation (CLPO) of methane to produce synthesis gas sustainably. The as-synthesized and used catalysts with varying kaolin and boehmite alumina contents (KB(x,y)/LSF) were scrutinized by a variety of characterization methods, including XRD, FE-SEM/EDS, BET, TPD-NH3, and TPD-O2 techniques. The catalytic activity of the synthesized samples was tested at 800 to 900 °C in a fixed-bed reactor producing syngas through the CLPO process over the consecutive redox cycles. Additionally, the attrition resistance of the fresh and used catalyst samples was examined in a jet cup apparatus to assess their durability against the stresses induced by thermal shocks or changes in the crystal lattice caused by chemical reactions. The characterization results showed the pure perovskite crystal structure of KB(x,y)/LSF catalysts demonstrating adequate oxygen adsorption capacity, effective coke mitigation capability, robust thermal stability, and resilience to agglomeration during repetitive redox cycles. Among the tested catalysts, KB(25,15)/LSF was identified as the superior sample, as it could consistently produce syngas with a suitable H2:CO molar ratio varying from 2 to 3 within ten redox cycles at 900 °C, with CH4 conversion and CO selectivity values up to 64% and 87%, respectively. The synthesized catalysts demonstrated a logarithmic attrition pattern in the jet cup tests at room temperature, featuring high attrition resistance after the erosion of particle shape irregularities or weakly bound particles. Moreover, the KB(25,15)/LSF catalyst used at 900 °C showed great resistance in the attrition test, warranting its endurance in the face of extraordinarily harsh conditions in fluidized bed reactors employed for the CLPO process.