Syngas production via CO2 reforming of methane over plasma assisted synthesized Ni‐Co/Al2O3‐ZrO2 nanocatalysts with different Ni‐loadings

Ni‐Co/Al₂O₃‐ZrO₂ nanocatalysts with 5, 10 and 15 wt.% nominal Ni content have been prepared by impregnation followed by a non‐thermal plasma treatment, characterized and tested for dry reforming of methane. For nanocatalysts characterization the following techniques have been used: XRD, FESEM, TEM, EDX dot‐mapping, BET, FTIR and XPS. The dry reforming of methane was carried out at different temperatures (550‐850 °C) using a feed mixture of CH₄:CO₂ (1:1). Among the nanocatalysts studied, the catalyst with the medium Ni content (10 wt.%) was the most active in dry reforming of methane. This higher activity exhibited by Ni‐Co/Al₂O₃‐ZrO₂ catalyst with medium Ni content (10 wt.% ) can be attributed to small and well dispersed particles of Ni within the catalyst. Apart from the narrow surface particle size distribution in the case of Ni(10 wt.%)‐Co/Al₂O₃‐ZrO₂, the presence of small active components with average size of 7.5 nm is proposed to be the reason for the superior performance of the catalyst. Ni(10 wt.%)‐Co/Al₂O₃‐ZrO₂ nanocatalyst had maximum surface area and the lower surface area was observed in the case of Ni(5 wt.%)‐Co/Al₂O₃‐ZrO₂ and Ni(15 wt.%)‐Co/Al₂O₃‐ZrO₂ due to the formation of the larger agglomeration and higher mean particle size of nickel particles, respectively. Although, GHSV enhancment had inverse effect on product yield but yield reduction for Ni‐Co/Al₂O₃‐ZrO₂ catalyst with 10 wt.% Ni was less drastic at high GHSVs. According to XRD and XPS, existence of NiAl₂O₄ confirms strong interaction between Ni and support but higher loadings of Ni resulted in less NiAl₂O₄; loser interaction between support and active phase. Small particles of active components and well‐defined dispersion of them in Ni(10 wt.%)‐Co/Al₂O₃‐ZrO₂ nanocatalyst resulted in stability of the catalyst for either feed conversion or H₂/CO molar ratio. Copyright © 2013 John Wiley & Sons, Ltd.