Hydrogen production using Ni-Cu catalysts with cement-clay composites in low-temperature methanol steam reforming

This study presents a sustainable approach for hydrogen production through methanol steam reforming (MSR), employing Ni-Cu catalysts supported on a composite of cement and clay. The use of this hybrid support offers multiple benefits over conventional metal oxide carriers, such as simplified synthesis, enhanced thermal stability, and improved reaction efficiency. Unlike traditional supports like Al 2 O 3 that require complex preparation and post-treatment, the cement-clay system undergoes only a single-step sintering, significantly reducing energy consumption. The mechanical and thermal properties of the composite are confirmed through compressive strength tests and thermogravimetric analysis, indicating minimal weight loss (<5 %) below 600 °C and strong structural integrity. Catalyst characterization reveals a high BET surface area (170.1 m 2 /g) and well-dispersed Ni-Cu particles, contributing to efficient methanol conversion and hydrogen evolution. The combined properties of Ni and Cu, thermal durability and catalytic activity, respectively, lead to a hydrogen concentration exceeding 30 %, with conversion efficiency surpassing 90 % and a hydrogen yield of 2.5 mol∙(mol CH 3 OH) −1 . Furthermore, cement's inclusion in the support suppresses undesirable methanation by altering reaction pathways and stabilizing intermediates. The cement–clay matrix thereby plays both a structural and catalytic role. Overall, the Ni-Cu/cement-clay catalyst system offers a cost-effective, scalable, and energy-efficient route for hydrogen production, making it a strong candidate for green energy applications. • Cement-clay supporters help reduce metal catalyst amounts for H 2 production. • Cement-clay supporters are highly stress-resistant, thermostable, and cost-efficient. • Composite Ni-Cu catalysts have high surface areas and perform the same as noble metals. • Ni-Cu cement-clay supporter has high H 2 conversion (>90 %) and yield (2.5 mol/mol CH 3 OH). • Cement suppresses methanation by forming cross-linked salt with clay and absorbing CO and CO 2 .