Novel Ni/SBA-15 Catalyst Pellets for Tar Catalytic Cracking in a Dried Sewage Sludge Pyrolysis Pilot Plant

Novel Ni/SBA-15 catalysts were synthesised and their activity in the dry reforming of methane process was assessed. These materials were prepared into extrudates shaped like pellets and tested in a pyrolysis pilot plant fitted with a catalytic reactor for sewage sludge pyrolysis tar removal. The Ni/SBA-15 catalyst pellets remained highly active and stable throughout the test’s duration, converting 100% tar in the hot gas to smaller non-condensable gases, thereby increasing the pyrolysis gas fraction and eliminating the problematic tar in the vapour stream. Catalyst characterisation with Scanning Electron Microscopy (SEM), Energy-Dispersive X-ray (EDX) analysis, Transmission Electron Microscopy (TEM), and Thermogravimetric Analysis (TGA) confirmed that both the Ni/SBA-15-powered catalyst and the pellets were resistant to sintering and carbon deposition and remained highly active even with relatively high-level sulphur in the feed stream. The Ni/SBA-15 catalyst extrudates were prepared by mixing the powdered catalyst with varied amounts of colloidal silica binder and fixed amounts of methyl cellulose and water. The highest mechanical strength of the extrudates was determined to be of those obtained with 36% of the inorganic binder. The physical properties and catalytic activity of Ni/SBA-15 pellets with 36% colloidal silica were compared with the original powdered Ni/SBA-15 catalyst to assess the binder inhibitory effect, if any. The results confirmed that colloidal silica binder did not inhibit the desired catalyst properties and performance in the reaction. Instead, enhanced catalytic performance was observed.