Comparative Study of Ni-Impregnated Alumina Aerogels and Ni-Al Xerogels for Light-Irradiation-Assisted CO2 Methanation

CO2 methanation is considered a key process in achieving carbon neutrality. Expanding on our previous study of supercritically dried Ni-Al aerogels, this work compares two gel-based catalyst families prepared via two different routes—supercritically dried Ni impregnated Al aerogel-based catalysts and oven-dried one-pot Ni-Al xerogel-based catalysts—to assess how the synthesis route affects catalyst structure and CO2 methanation performance under light irradiation. The catalysts were subsequently characterized via different techniques, such as ICP-OES, N2 adsorption–desorption isotherms, XRD, H2-TPR, UV-vis DRS, XPS, and TEM. Catalytic activity was tested in a photoreactor at a range of temperatures from 300 °C to 450 °C and 10 bar pressure, and two different light sources were used (λ = 365 nm, λ = 470 nm). Both light sources enhanced catalytic activity in most cases; the xerogels with higher Ni loadings were the most active materials. These catalysts reached CO2 conversions and CH4 selectivities near 70% and 100%, respectively. The results indicate that drying gels is a promising method for synthesizing catalysts active in the Sabatier reaction, given the properties of the materials.