Ni-Based Catalysts Coupled with SERP for Efficient Power-to-X Conversion

The industrial application of CO2 methanation in Power-to-X (P2X) systems requires the development of highly active catalysts capable of operating at milder temperatures to ensure energy efficiency, while exhibiting high activity, stability and selectivity. This study reports the synthesis and optimization of Ni-based catalysts on Al2O3 supports, guided by a Design of Experiments (DoE, 24 factorial design) approach. Initial optimization afforded a robust catalyst achieving 80% CO2 conversion and >99% CH4 selectivity at 325 °C. Remarkably, the incorporation of CeO2 traces to the Ni-based catalyst substantially boosted catalytic activity, enabling higher conversions at temperatures up to 75 °C lower than the unpromoted catalyst. This improvement is attributed to Ni–CeOx synergy, which facilitates CO2 activation and Ni reducibility. Both formulations exhibited exceptional long-term stability over 100 h. Furthermore, process intensification via the Sorption-Enhanced Reaction Process (SERP) with the Ni-based catalyst demonstrated even superior efficiency, rapidly increasing CO2 conversion beyond 95% with the same selectivity range. Our findings establish a clear and consistent pathway for industrial CO2 valorization through next-generation P2X technology for high-purity synthetic natural gas (SNG) production. This process offers an efficient and sustainable route toward industrial defossilization by converting captured CO2 and green H2 into SNG that is readily usable within the existing energy infrastructure.