Response surface optimization of syngas production from greenhouse gases via DRM over high performance Ni–W catalyst

The process parameters for dry reforming of methane (DRM) over Ni–W/Al₂O₃–MgO catalyst are optimized using response surface methodology (RSM). The Ni–W bimetallic catalyst is synthesized by co-precipitation method followed by impregnation. The catalysts are characterized by BET, XRD, FESEM, EDX and TEM; to study physicochemical properties, morphology, composition, crystallite size and deposited carbon. The effect of process parameters, i.e., reaction temperature (600^oC–800 °C) and feed gas ratio (0.5–1.5) on the CH₄, CO₂ conversions and syngas ratio are studied. A temperature of 777.29 °C with CH₄: CO₂ of 1.11 at GHSV of 36,000 cm³gm.cat⁻¹h⁻¹, delivered the CH₄ and CO₂ conversions of 87.6% and 93.3%, respectively along with H₂:CO of 1. The predicted process parameters were verified through actual experimental analysis at the optimized conditions, and results agreed with CCD of the RSM model with insignificant error. The MWCNT formed during DRM avoided catalyst deactivation and delivered stable performance over 12 h of reaction test at the optimized conditions.