Influence of Alumina and Silica Supports on the Performance of Nickel Catalysts for Methane Partial Oxidation

Rising greenhouse gas concentrations are causing climatic change that threatens ecosystem sustainability. This study investigated the impact of silica incorporation into alumina-supported nickel catalysts for the partial oxidation of methane (POM), a crucial process for syngas production. The investigation also focuses on the impact of using different calcination temperatures. The catalysts were synthesized using the impregnation method and structurally characterized with BET, TPR, FTIR, UV, XRD, TGA, Raman, and TEM analysis techniques. These characterization techniques revealed that increasing the silica content reduced the surface area and weakened the interaction between nickel and the support. The calcination temperature significantly influenced catalyst properties, affecting pore structure, nickel reducibility, and the formation of nickel aluminates and silicates. Activity tests of synthesized catalysts were performed in a packed-bed reactor at 600 °C with a 24 mL/min gas flow rate. The catalyst composition of 5Ni/10Si + 90Al demonstrated the highest activity, achieving optimal performance at lower calcination temperatures. This catalyst generates a greater concentration of active sites, primarily due to nickel oxide (NiO), which creates these sites through both mild and strong interactions. The degree of graphitization is notably lowest for the 5Ni/10Si + 90Al composition. This catalyst achieved an impressive hydrogen yield of approximately 54%, with an H2/CO ratio of 3.4 over a streaming period of up to 240 min. When the silica loading exceeds 10 wt.%, the interaction between the metal and the support weakens, resulting in a significant decrease in surface area and, subsequently, lower catalytic activity. The 5Ni/10Si + 90Al catalyst, which was prepared with calcination temperatures above 500 °C, has very few active sites during the Partial Oxidation of Methane (POM) reaction at a reaction temperature of 600 °C. This catalyst also exhibits a high degree of crystallinity, which leads to reduced exposure of the active sites. As a result, incorporating higher weight percentages of silica into the 5Ni/xSi + (100 − x) Al catalysts results in decreased activity. When the silica loading exceeds 10 wt.%, the interaction between the metal and the support weakens, resulting in a significant decrease in surface area and, subsequently, lower catalytic activity. The 5Ni/10Si + 90Al catalyst, which was prepared with calcination temperatures above 500 °C, has very few active sites during the POM reaction at a reaction temperature of 600 °C. This catalyst also exhibits a high degree of crystallinity, which leads to reduced exposure of the active sites. As a result, incorporating higher wt.% of silica into the 5Ni/xSi + (100 − x) Al catalysts results in decreased activity. These findings highlight the complex interplay between silica content, calcination temperature, and catalyst properties, significantly influencing catalytic performance in POM.