Influence of Low Metal Loading on the Catalytic Activity and Stability of Supported Metal Catalysts for Methane Dry Reforming

This study aims to utilize highly active nickel catalysts supported by zirconia for the dry reforming of methane (DRM). The catalysts were prepared with a low nickel loading of 5 wt%. This study seeks to investigate how the limited nickel content (5 wt%) and various preparation methods impact the properties of the catalysts as well as their performance during the DRM reaction. To assess the physicochemical properties of the catalysts, several techniques were employed, including X-ray diffraction (XRD), N2 physisorption, Fourier transform infrared spectroscopy (FTIR), and scanning electron microscopy (SEM). The evaluation of the activity and stability of the synthesized catalysts demonstrated that a specific configuration of the Ni/ZrO2 catalyst exhibited the best performance. The study further revealed a clear distinction between the two preparation methods. Catalysts prepared via co-precipitation displayed high activity of methane conversion (53%) and carbon dioxide conversion (55%) across all tested temperatures and maintained stability throughout the reaction. In contrast, catalysts synthesized through impregnation exhibited lower activity at all temperatures and were deactivated during the testing period. The observed catalytic activity can be attributed to a combination of factors, including highly dispersed NiO particles and a high number of oxygen vacancies within the catalyst structure. These findings underscore the critical role of catalyst preparation methods and the resulting physicochemical properties, such as phase composition and particle size, in determining catalytic performance. This highlights the potential for further enhancing the performance of these catalyst systems through optimization of preparation methods and exploration of novel support materials for the development of more efficient and sustainable DRM technologies.