Unveiling the catalytic performance of unique core-fibrous shell silica-lanthanum oxide with different nickel loadings for dry reforming of methane

The dry reforming of methane (DRM) stands as a remarkable process for the conversion of methane and carbon dioxide into syngas (H2/CO). In this study, mesoporous fibrous silica lanthanum oxide-supported nickel catalysts (NSLF-x) with various nickel loadings (3 to 15 wt%) were efficiently fabricated using the microemulsion and impregnation approaches, respectively, to conduct DRM. The results obtained from FESEM and TEM revealed the presence of a unique core-fibrous shell-structured morphology of silica lanthanum oxide support (SLF). Furthermore, XRD and SEM-EDS analyses indicated that the structural integrity of SLF remained consistent regardless of the amount of Ni loading, while the size of NiO nanocrystalline varied with the quantity of Ni loading. Notably, H2-TPR analysis emphasized that the NSLF-15 catalyst exhibited the strongest metal-support interaction among the catalysts. Due to this reason, it exhibited outstanding catalytic activity and stability in terms of CO2 conversion (86.7 %), CH4 conversion (87 %), and a high H2/CO ratio at 750 °C, demonstrating high thermal stability after 28 h without any signs of deactivation. The superior catalytic performance of NSLF-15 catalysts, along with their ability to activate CH4 and CO2, can be attributed to the synergistic effects resulting from the enhanced physicochemical properties and the unique morphology. Additionally, the results from TEM, Raman, and TGA analyses also indicated the presence of non-filamentous carbon and filamentous carbons with accumulation of Ni species due to the elevated temperature of the reaction. Overall, the NSLF-15 catalysts hold significant potential for industrial-scale application for syngas formation.