Alumina Coated with Titanium Dioxide Supported Iron for Hydrogen Production and Carbon Nanotubes via Methane Decomposition

Research on converting methane to hydrogen has gained more attention due to the availability of methane reserves and the global focus on sustainable and environmentally friendly energy sources. The decomposition of methane through catalysis (CDM) has excellent potential to produce clean hydrogen and valuable carbon products. However, developing catalysts that are both active and stable is a highly challenging area of research. Using titanium isopropoxide as a precursor and different loadings of TiO2 (10 wt.%, 20 wt.%, and 30 wt.%), alumina has been coated with TiO2 in a single-step hydrothermal synthesis procedure. These synthesized materials are examined as possible support materials for CDM; different wt.% of iron is loaded onto the synthesized support material using a co-precipitation method to enhance the methane conversion via a decomposition reaction. The result shows that the 20 wt.% Fe/20 wt.% Ti-Al (20Fe/20Ti-Al) catalyst demonstrates remarkable stability and exhibits superior performance, reaching a conversion rate of methane of 94% with hydrogen production of 84% after 4 h. The outstanding performance is primarily due to the moderate interaction between the support and the active metal, as well as the presence of the rutile phase. The 20Fe/30Ti-Al catalyst exhibited lower activity than the other catalysts, achieving a methane conversion of 85% and hydrogen production of 79% during the reaction. Raman and XRD analysis revealed that all the catalysts generated graphitic carbon, with the 20Fe/20Ti-Al catalyst specifically producing single-walled carbon nanotubes.