Double-Flame Spray Pyrolysis Synthesized Stabilized Cobalt Nanoparticles for Dry Reforming of Methane

The CO2 dry reforming of methane (DRM) to produce hydrogen-rich syngas offers a promising solution transforming two major greenhouse gases into a high-value product. DRM has the potential for commercial application, but the limited stability of catalysts poses a significant barrier to its widespread application. Flame spray pyrolysis (FSP) has emerged as an innovative technique for designing catalysts with distinct structures that enhance both activity and durability. In this study, double-flame spray pyrolysis (DF-FSP) has been utilized to design cobalt-based nanoparticles on an alumina support. The DF-FSP results in the formation of an interfacial layer of CoxAlyO4, which acts as an adhesive layer between the cobalt nanoparticles and the Al2O3 support. This interfacial layer stabilizes the cobalt active sites for over 80 h during DRM at 700 °C, achieving a CO2 conversion rate of 68.6%. In contrast, a conventionally synthesized Co/Al2O3 catalyst, lacking this interfacial layer, exhibited complete deactivation within 7 h and a maximum CO2 conversion of 67.7%. The DF-FSP thus presents a compelling alternative for synthesizing catalysts with interfacial stable adhesive layers, resulting in state-of-the-art performance for challenging catalytic reactions.