Cost-Effective Single-Step Synthesis of Metal Oxide-Supported Ni Catalyst for H₂-Production Through Dry Reforming of Methane

Preparing catalysts from cheap metal precursors in a single pot are an appealing method for reducing catalytic preparation costs, minimizing chemical waste, and saving time. With regards to the catalytic conversion of dry reforming of methane, it offers the prospect of significantly reducing the cost of H-2 production. Herein, NiO-stabilized metal oxides like Ni/TiO2, Ni/MgO, Ni/ZrO2, and Ni/Al2O3 are prepared at two different calcination temperatures (600 degrees C and 800 degrees C). Catalysts are characterized by X-ray diffraction, Raman spectroscopy, surface area-porosity analysis, Temperature program experiments, infrared spectroscopy, and thermogravimetry analysis. The MgO-supported Ni catalyst (Ni/MgO-600), ZrO2-supported Ni catalyst (Ni/ZrO2-600), and Al2O3-supported Ni (Ni/Al2O3-600) catalyst calcined at 600 degrees C show initial equal H-2 yields (similar to 55%). The population of CH4 decomposition sites over ZrO2-supported Ni catalyst remains highest, but H-2-yield drops to 45% against high coke deposition. The catalytic activity remains constant over the Ni/MgO-600 catalyst due to the enrichment of "surface interacted CO2-species". MgO-supported Ni catalyst calcined at 800 degrees C undergoes weak interactions of NiO-M ' (M ' = support), serious loss of CH4 decomposition sites and potential consumption of H-2 by reverse water gas shift reaction, resulting in inferior H-2 yield. H-2-yield remains unaffected over an Al2O3-supported Ni catalyst even against the highest coke deposition due to the formation of stable Ni (which exsolves from NiAl2O4) and proper matching between carbon formation and rate of carbon diffusion.