भारतीय प्रौद्योगिकी संस्थान (का.हि.वि.) वाराणसी

Thermocatalytic conversion of Carbon dioxide into Ethanol and higher alcohols

Several studies have shown that the concentration of carbon dioxide(CO2) in the atmosphere is increasing to an alarming level. This increase in carbon dioxide concentration has shown a direct link between global warming and abnormal climatic pattern. The use of carbon dioxide as a source of fuel production will not only help in reducing the pollution level but can also show a new path to alternate fuel sources such as ethanol and dimethyl ether. 

Hydrogen production using hydrocarbon/biogas reforming

Our research group focuses on the development of advanced nickel-based and nanostructured composite catalysts for the bireforming of methane and biogas reforming to produce syngas with tunable H₂/CO ratios. Bireforming integrates steam reforming and dry reforming processes, enabling efficient utilization of CH₄ and CO₂ while reducing greenhouse gas emissions. We design high-performance nano-catalysts, including supported Ni catalysts, core–shell structures, and metal–oxide composites, to achieve enhanced catalytic activity, coke resistance, thermal stability, and long-term durability under industrially relevant conditions. Our work combines catalyst synthesis, characterization, reaction engineering, and mechanistic studies to develop sustainable pathways for hydrogen and value-added chemical production from natural gas and renewable biogas resources.

Catalytic upgradation of methane into valuable chemicals

Our research group is actively engaged in the development of advanced catalysts and reactor technologies for the oxidative coupling of methane (OCM), aiming for the direct conversion of methane into higher-value hydrocarbons such as ethylene and ethane. Our work focuses on modified Li/MgO and Na–Mn–W/SiO₂ catalyst systems, which are recognized for their promising activity, selectivity, and thermal stability in OCM reactions. We investigate catalyst modification strategies, nanostructured composites, and promoter effects to improve methane conversion and C₂ selectivity while minimizing deep oxidation products. In parallel, we explore the application of structured reactors, including monolith and microchannel configurations, to enhance heat management, mass transfer, and process intensification for scalable and energy-efficient methane valorization. Through integrated catalyst and reactor design, our research aims to advance sustainable technologies for natural gas and biogas utilization.

Selective oxidation of n-butane to maleic anhydride

Our research group is also working on the selective oxidation of n-butane to maleic anhydride (MA) through advanced catalytic and reactor engineering approaches under a sponsored research program with Bharat Petroleum Corporation Limited. The research focuses on the application of micro- and milli-structured reactors for process intensification, enabling superior heat and mass transfer, improved temperature control, and enhanced process safety for highly exothermic oxidation reactions. We are also developing robust catalyst coating and washcoating methodologies for structured reactor surfaces to achieve uniform catalyst distribution, strong adhesion, and long-term catalytic stability. The work integrates catalyst synthesis, structured reactor fabrication, coating optimization, and reaction studies to advance efficient and scalable technologies for the production of maleic anhydride.

Development of new structured reactors for chemical process intensification

Due of their effective catalyst utilization, lower pressure drops, and improved heat transfer capabilities, catalytic structured reactors can become a key aspect of chemical process intensification. Depending on the scale of operation, they can be either used as a micro-reactor for onboard hydrogen generation in mobile vehicles or can be a replacement for a packed bed reactor used in the steam reforming methane process, etc.

As the material of construction and design of these reactors has a significant effect on their efficiency, several kinds of structured reactors made from alumina, ceramic, copper and stainless steel with different geometrical designs have been tested by various researchers. The choice of the material of construction strongly depends on the chemical process requirement. The process, like steam reforming of methane, which requires very high temperature due to its endothermic nature, uses a metallic structured reactor, which can provide several benefits. Metallic structured reactors, due to their high thermal conductivity, provide better temperature distribution inside the reactor and result in better reactor efficiency.

Institute Seed Research Grant

IIT(BHU) Varanasi

2021-2022

Grant: 10,00,000 INR

Project Title: Thermo-catalytic conversion of carbon dioxide into ethanol and higher alcohols
Funding Agency: Science and Engineering Research Board, Government of India
Funding Amount(₹): 33,00,000
Duration: 2 Years (completed)

Project Title: Development of catalytic structured reactors for carbon dioxide methanation
Funding Agency: Council of Science and Technology, Govt. of Uttar Pradesh, India
Funding Amount(₹): 7,50,000
Duration: 3 Years

Project Title: Catalyst Coating on Milli Channel Reactors for Maleic Anhydride Production
Funding Agency: BPCL Corporate R&D Center, Noida, India
Funding Amount(₹): 62,87,000
Duration: 2 Years

Project Title: Development Of Catalytic Structured Reactors for Oxidative Coupling Of Methane Reaction
Funding Agency: ANRF India, India
Funding Amount(₹): 59,64,480
Duration: 3 Years
 

• CHE241: Industrial Pollution Control (2020-21 Even Semester)

• CHE451: Heterogeneous Catalysis (2021-22 Odd Semester)

• CHE211: Equipment Design (2022-23 Even Semester)

•  CHE451: Heterogeneous Catalysis (2022-23 Odd Semester)

• CHE241: Industrial Pollution Control (2022-23 Even Semester)

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• Mass Transfer Laboratory

• Instrumentation Laboratory

• Pollution Control Laboratory

Journal Publications

Sanjay Katheria, Abhishek Gupta, Goutam Deo and Deepak Kunzru, “Effect of calcination temperature on stability and activity of Ni/MgAl2O4 catalyst for steam reforming of methane at high pressure condition”, International Journal of Hydrogen Energy, 32 (2016) 14123-14132

Sanjay Katheria, Goutam Deo and Deepak Kunzru, “Washcoating of Ni/MgAl2O4 catalyst on FeCralloy monoliths for steam reforming of methane”, Energy&Fuels, 31 (2017) 3143-3153

Vinod K. Jaiswar1, Sanjay Katheria1, Goutam Deo and Deepak Kunzru, “Effect of Pt doping on activity and stability of Ni/MgAl2O4 catalyst for steam reforming of methane at high pressure condition”, International Journal of Hydrogen Energy, 42 (2017) 18968-18976 (1First two authors with equal contribution)

Sanjay Katheria, Goutam Deo and Deepak Kunzru, “Rh-Ni/MgAl2O4 catalyst for steam reforming of methane: Effect of Rh doping, calcination temperature and its application on metal monoliths”, Applied Catalysis A: General, 570 (2019) 308-318

Rajesh Thattarathody, Sanjay Katheria and Moshe Sheintuch, “Methylal steam reforming with Pt/Al2O3, Ni/Al2O3 and mixed Cu/ZnO/Al2O3 catalysts”, Industrial & Engineering Chemistry Research, 58 (2019), 21382-21391

Sanjay Katheria, Goutam Deo and Deepak Kunzru, “Kinetics of steam reforming of methane on Rh–Ni/MgAl2O4 catalyst”, Reaction Kinetics, Mechanisms and Catalysis, 130 (2020) 91-101

Conferences

Sanjay Katheria, Abhishek Gupta, Goutam Deo, Deepak Kunzru, "Effect of calcination temperature on stability and activity of Ni/MgAl2O4 catalyst for steam reforming of methane" European Congress on Catalysis (EuropaCat-XII), Kazan, Russia, Aug.30-Sep.4, 2015

Sanjay Katheria, Abhishek Gupta, Goutam Deo, Deepak Kunzru, "Washcoating of FeCralloy metal monoliths with Ni/MgAl2O4", CHEMCON, 2015, Guwahati, India, Dec.27-30, 2015

Prasoon Srivastava, Sanjay Katheria, Vinod Kumar, Goutam Deo, Deepak Kunzru, "Effect of adding noble and non-noble metals to Ni/MgAl2O4 catalyst on the high-pressure activity of steam reforming of methane", Asia-Pacific Congress on Catalysis (APCAT) 2017, Mumbai, India, Jan. 17-21, 2017

Sanjay Katheria, Goutam Deo, Deepak Kunzru, "Promotional effect of Rh on Ni/MgAl2O4 catalyst for steam reforming of methane: Effect of calcination temperature" South East Asia Catalysis Conference, Singapore, May 22-23, 2017

Room No. 215

First Floor, Department of Chemical Engineering & Technology,

Indian Institute Of Technology(BHU), Varanasi,

Varanasi-221005, Uttar Pradesh,

India

Email id: sanjay.che(at)iitbhu.ac.in

Contact Number: +91 951 915 2929