Future Paradigm of 3D Printed Ni-Based Metal Organic Framework Catalysts for Dry Methane Reforming: Techno-economic and Environmental Analyses

Dry reforming of biogas is referred as an attractive path for sustainable H₂ production over decades. Meanwhile, in the Malaysian context, the abundance of palm oil mill effluent (POME) produced annually is deemed as a potential renewable source for renewable energy generation. Conventionally, nickel (Ni) is the most common catalyst used in the industrial-scale dry reforming of methane (DRM) to yield H₂, but it is subject to the drawbacks of sintering and deactivation after a long reaction time at high temperatures (>500 °C). Therefore, this work aims to provide an insight on the feasibility of the application of modified Ni-based catalysts in DRM, specifically in the economic and environmental aspects. From the benchmarking study of various Ni-based catalysts (e.g., bimetallic (Ni-Ce/Al₂O₃), alumina support (Ni/Al₂O₃), protonated titanate nanotube (Ni-HTNT), and unsupported), the Ni-MOF catalyst, notably, had proven its prominence in both economic and environmental aspects on the same basis of 10 tonnes of H₂ production. The MOF-based catalyst not only possessed a better economic performance (net present value 61.86%, 140%, and 563.08% higher than that of Ni-Ce/Al₂O_3, Ni/Al₂O₃, and Ni-HTNT) but also had relatively lower carbon emissions (13.18%, 20.09%, and 75.72% lower than that of Ni/Al₂O₃, Ni-HTNT, and unsupported Ni). This work also accounted for 3D printing technology for the mass production of Ni-MOF catalysts, where the net present value was 2 to 3% higher than that of the conventional production method. Additionally, sensitivity analysis showed that the H₂ price has the greatest impact on the feasibility of DRM as compared to other cost factors.