Autothermal Reforming of Natural Gas for Synthesis Gas Production: Catalyst Deactivation and Regeneration

Abstract

Autothermal reforming of natural gas is a widely employed industrial process for synthesis gas production due to its ability to integrate partial oxidation and steam reforming reactions within a single reactor system. The present study investigates autothermal reforming of natural gas with emphasis on catalyst deactivation mechanisms and regeneration performance under industrial operating conditions. The research focuses on evaluating the influence of reaction temperature, steam-to-carbon ratio, oxygen feed concentration, and operating duration on catalyst activity, synthesis gas composition, and carbon deposition behavior. Experimental analysis demonstrates that catalyst deactivation primarily occurs due to carbon accumulation, thermal sintering, sulfur poisoning, and active metal surface degradation during prolonged reforming operation. Results indicate that elevated operating temperatures and optimized reactant feed conditions significantly improve methane conversion and hydrogen production while reducing coke formation on catalyst surfaces. The study further reveals that regeneration strategies involving controlled oxidation and thermal treatment effectively restore catalytic activity and improve long-term operational stability. Catalyst characterization analyses confirm that repeated regeneration cycles can recover active surface sites and enhance resistance to deactivation under continuous reforming conditions. Comparative assessment with conventional steam reforming processes highlights the advantages of autothermal reforming, including lower energy demand, compact reactor configuration, and improved process efficiency for synthesis gas generation.