An X-ray diffraction computed tomography study determining failure mechanisms in industrial Cu/ZnO/Al2O3(−Cs2O) water–gas shift catalysts
An X-ray diffraction computed tomography study determining failure mechanisms in industrial Cu/ZnO/Al2O3(−Cs2O) water–gas shift catalysts
Authors (10): S. Stockenhuber, D. M. Farmer, D. Farooq, M. A. Molina, A. Vamvakeros, S. W. T. Price, V. Honkimaki, D. Waller, S. Gopinathan, A. M. Beale
Themes: Core
DOI: 10.1016/j.jcat.2026.117088
Citations: 0
Pub type: journal-article
Pub year: 2026

Publisher: Elsevier BV

Issue:

License: [{"start"=>{"date-parts"=>[[2026, 10, 1]], "date-time"=>"2026-10-01T00:00:00Z", "timestamp"=>1790812800000}, "content-version"=>"tdm", "delay-in-days"=>0, "URL"=>"https://www.elsevier.com/tdm/userlicense/1.0/"}, {"start"=>{"date-parts"=>[[2026, 10, 1]], "date-time"=>"2026-10-01T00:00:00Z", "timestamp"=>1790812800000}, "content-version"=>"tdm", "delay-in-days"=>0, "URL"=>"https://www.elsevier.com/legal/tdmrep-license"}, {"start"=>{"date-parts"=>[[2026, 7, 27]], "date-time"=>"2026-07-27T00:00:00Z", "timestamp"=>1785110400000}, "content-version"=>"vor", "delay-in-days"=>0, "URL"=>"http://creativecommons.org/licenses/by/4.0/"}]

Publication date(s): 2026/10 (print)

Pages: 117088

Volume: 462 Issue:

Journal: Journal of Catalysis

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The water–gas shift (WGS) reaction is a key process for industrial hydrogen production used in ammonia synthesis, where Cu–Zn–Al (CZA) catalysts are typically employed. Since similar formulations are also used for methanol synthesis, 1 wt% Cs2O is often added to mitigate its formation as an unwanted side product. However, this addition has recently been suggested to decrease the mechanical strength of the catalyst, particularly during initial reduction, leading to premature failure. In this study, we investigate how gas composition (particularly water content) and pressure affect the structural and chemical evolution of recovered CZA pellets after a typical reduction protocol, using quasi-in situ X-ray Diffraction Computed Tomography (XRD-CT). We find that high water content (∼20 vol%) combined with increasing Cs2O loading markedly promotes Cu0 crystallite growth, favours formation of Cu2O, and enhances ZnO sintering. These effects are most severe at the pellet periphery and ultimately compromise mechanical integrity. The results highlight the critical interplay between steam, pressure, and Cs promotion in governing catalyst stability during activation.

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