NiFeMnBaPr perovskite Pre-Catalysts for stable steam reforming of heavy crude oil

• Steam reforming of crude oil to hydrogen enabled by a perovskite-based catalyst. • The catalyst is based on a NiFePrBaMn pre-catalyst. • Arabian heavy is centrifuged to reduce the asphaltenes and then fed directly. • The catalyst composition helped to sustain the activity and stability. • Continued hydrogen production for 30 h, a 10x increase over previous catalysts. This study evaluates the stability and activity of Pr 0.5 Ba 0.5 Mn 0.8 Ni 0.15 Fe 0.05 O 3 perovskite pre-catalyst, demonstrating its capability to resist deactivation and produce hydrogen under the challenging conditions required for reforming heavy crude oil. Operating at 800 °C, the catalyst achieved an 88 % conversion, yielding a hydrogen-rich gas stream (54 mol% H 2 ) with minimal pressure buildup, outperforming the “traditional” NiCoCeMgAl catalysts (stable for 3 h) by maintaining stability for 30 h. The catalyst resistance against carbon deposition and sulfur is enhanced through a unique composition, which enables efficient coke gasification and the formation of phases that keep the activity. These phases formed during the reaction (NiS x , NiC, Fe 2 O 3 , FeC, and MnO x ) contribute to prolonged activity by releasing oxygen to react with carbonaceous deposits. Our work highlights the potential for hydrogen production from heavy crude oil and establishes a pathway for developing highly durable catalysts for industrial applications.