Highly active nickel-based fibrous silica ZnO (NSZF) catalyst for efficient syngas production through dry reforming of methane

In this study, a highly active catalyst was synthesized using microemulsion and impregnation methods for dry reforming of methane (DRM). The catalyst was developed by incorporating ZnO as a co-support inside the silica fibrous framework, acting as a core in the fibrous shell of the silica structure (SZF). The catalysts were analyzed using XRD, FESEM, EDX, XPS, TEM, FTIR, and BET techniques. The spent catalysts were also examined by XRD, TEM, Raman spectroscopy, and TGA to examine alterations in morphology and carbon deposition. It was found that the incorporation of ZnO improved the selectivity of hydrogen during the DRM reaction. Among the tested catalysts, NSZF-10 (10 wt% Ni) exhibited remarkable efficiency in the DRM reaction, achieving methane (CH₄) and carbon dioxide (CO₂) conversions of 82 % and 74 %, respectively, over a 40-h reaction period at 750 °C. The amount of Ni over the SZF support played a significant role in boosting overall catalytic performance. Additionally, the improved textural and morphological properties of the SZF, and the strong metal support interaction in which ZnO bonded the optimum loading amount of Ni nanoparticles in the SZF framework. Furthermore, the fibrous shell of silica acted as a protective barrier for the Ni nanoparticles, impeding their migration to the catalyst's surface. The long-term stability of the NSZF-10 catalyst confirmed their coke resistance with minimal carbon deposition and without changes in morphological structure.