Scalable Exsolution‐Derived E‐Ni/m‐MgAlO x Catalysts with Anti‐Sintering Stability for Methane Dry Reforming

Abstract Sintering and carbon deposition are primary causes of deactivation in Ni‐based catalysts during methane dry reforming (MDR). To address these issues, a scalable exsolution‐derived catalyst, E‐Ni/m‐MgAlO x , is reported, consisting of ≈9 nm Ni nanoparticles exsolved within a Mg‐doped mesoporous alumina matrix via a sol–gel method. This synthesis strategy ensures uniform precursor mixing and controlled exsolution, producing firmly anchored Ni nanoparticles with strong metal‐support interactions that effectively suppress sintering and coking. The incorporation of Mg promotes the formation of a stable MgAl 2 O 4 spinel phase and enhances surface basicity, thereby facilitating efficient CO 2 activation. The catalyst demonstrates high activity and excellent long‐term stability under high‐temperature MDR conditions (800 °C–900 °C, CH 4 /CO 2 /N 2 = 1:1:8, >1000 h), achieving a cumulative greenhouse gas conversion exceeding 20000 L·g cat −1 . Moreover, the synthesis process is straightforward, scalable, and highly promising for improving the durability of Ni‐based catalysts.