Zn-incorporated joule-heated carbon nanofiber aerogel-supported Cu catalyst for hydrogen production via methanol steam reforming

Conventional Cu-based catalysts are affected by disadvantages, such as uneven temperature distribution, non-uniformity of mass and heat transfer, slow heating rate, and difficult replacement. To address these, a three-dimensional (3D) Zn-incorporated Joule-heated carbon nanofiber aerogel (CNFA)-supported Cu catalyst, was prepared via a facile one-pot method. The optimized catalyst, Cu10–Zn10/CNFA, exhibited an 83.1% conversion of CH3OH and 0.01% selectivity of CO at 250 °C. This improvement was due to Zn species acting as both an isolating agent, which inhibited thermal transmigration and aggregation of Cu-containing nanoparticles during heat treatment, and a combining agent, which provided numerous Cu–ZnO interfaces that enabled strong interactions between Cu and ZnO, which improved the activity and stability of the methanol steam reforming (MSR) reaction. This study reveals the feasibility of utilizing Joule-heated CNFA-supported catalysts for MSR reactions and opens a new avenue for designing and fabricating 3D-ordered porous catalysts related to this transformation.