Ultra-fine Nickel Powder 【R&D】
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As technologies that enable a low-carbon society to continue to advance, catalyst performance and manufacturability are becoming increasingly important. Nickel (Ni) offers an attractive balance of cost, activity, and scalability, and is expected to play a key role in a wide range of reactions—including methanation.
However, realizing high catalyst performance requires careful optimization, including the metal’s intrinsic properties as well as dispersion and distribution within the support. Leveraging wet-chemical synthesis know-how established through its ultra-fine nickel powders, Sumitomo Metal Mining is developing nickel-based catalysts and slurry dispersions for methanation. This article outlines the technical advantages of these solutions and discusses potential applications beyond methanation.
Nickel-based catalysts for methanation
Methanation is a clean-energy technology attracting growing interest. It produces methane (CH₄) by reacting hydrogen (H₂) with carbon dioxide (CO₂), and is considered a promising way to reduce dependence on fossil resources.
A key to improving methanation efficiency is the use of base-metal catalysts, mainly made from nickel (Ni) . Sumitomo Metal Mining has developed a nickel-based catalyst suited for the methanation (Sabatier) reaction.
Methanation via the Sabatier reaction is generally carried out at around 400°C, but this newly developed catalyst shows high activity even at lower temperatures (around 230°C), achieving a CO₂ conversion rate of 80% or more.
This nickel-based catalyst is produced using Sumitomo Metal Mining’s core technology: nickel fine-particle synthesis (crystallization technology). Crystallization technology makes it possible to tune particles to properties suitable for catalysts.
In addition, Sumitomo Metal Mining has developed an “ultra-fine nickel powder slurry dispersion” designed to make it easier to impregnate porous catalyst supports with fine nickel particles suitable for methanation. This enables large amounts of catalyst particles to be introduced into the support in a single step, improving ease of catalyst preparation.
How nickel slurry expands potential applications
The value of ultra-fine nickel powder and nickel slurry is not limited to methanation-specific materials. Potential applications include:
• Catalysts for chemical reactions such as hydrocarbon reforming and hydrogenation
• Fuel cells and various electrode materials
• Conductive pastes
• Magnetic materials
• Electromagnetic interference (EMI) shielding materials
• Sintering materials and more
This broad range of possibilities is enabled by both the powder’s intrinsic properties and the flexibility of handling it as a slurry. Sumitomo Metal Mining’s ultra-fine nickel powder is produced via a wet process and features:
• Ultra-fine particles below 0.1 micrometers
• A uniform particle size distribution
• High dispersibility
• Low levels of impurities derived from organic substances
These characteristics contribute to easier handling when the material is formulated into a slurry.
Demand for nickel-based materials is expected to expand across decarbonization and hydrogen-related fields—ranging from methanation to fuel cells, electrodes, and other catalytic processes.
When considering a material for adoption, it is important to evaluate not only particle size and size distribution, but also:
• Dispersion stability
• Impregnation performance into supports
• Durability under reaction conditions
• Compatibility with the customer’s manufacturing process
As a starting point for such evaluations, X-MINING provides a platform to help users understand material information and support comparisons—connecting these insights to the next stage of co-creation. The platform also features related columns and technical information (materials and implementation). If you have a theme you are currently exploring, feel free to contact us through the X-MINING inquiry form.
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Written by: X-MINING Editorial Team
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