(628f) Application of Reaction Engineering Principles in Enhancing Catalytic Efficiency: Ni-MgA2O4/Carbon Foam for Dry Reforming of Methane

Dry reforming reactions offer an opportunity for the catalytic conversion of light alkanes into synthesis gas. Ni-based catalysts are promising due to their high activity and low cost, but they suffer from poor stability caused by coke formation and metal sintering. In this study, we synthesized a series of Ni-based spinel oxides (Ni/MgAl₂O₄, Ni/CoAl₂O₄, Ni/ZnAl₂O₄, and Ni/FeAl₂O₄) through impregnation method for dry reforming of methane at 800°C. Among these catalysts, the Ni/MgAl₂O₄ catalyst exhibited higher activity and better stability when using a stoichiometric feed ratio (1:1). The MgAl₂O₄ spinel layer effectively suppressed the phase transformation into NiAl₂O₄ spinel phases while stabilizing well-dispersed tiny crystallites of Ni, contributing to the good stability of the catalyst.

Reactor simulation results revealed that adding an inert diluent significantly improved the performance of the Ni/MgAl₂O₄ catalyst by reducing temperature gradient in the catalyst bed. We carried out an experiment by adding SiO₂ as an inert diluent and found that using a ratio of 1:3 for Ni/MgAl₂O₄:SiO₂ improved its performance by approximately 15%. Based on these findings, we desired to optimize the performance of catalyst from the point of view of reaction engineering. We designed a flat plate monolithic catalyst named Ni-MgAl₂O₄/carbon foam which demonstrated superior catalytic activity and stability under 800°C .