Dry reforming of methane to hydrogen-rich syngas over robust fibrous KCC-1 stabilized nickel catalyst with high activity and coke resistance

A remarkably stable and active nickel (Ni) catalyst, supported on fibrous KCC-1 silica particles, was prepared by in situ one-pot hydrothermal method to produce a hydrogen-rich syngas. The catalysts’ properties were characterized by BET, XRD, FESEM-mapping, FTIR-pyrrole, FTIR-KBr, and XPS, while coke deposition was evaluated using Raman spectra, TEM and TGA/DTA. The high dispersion of Ni crystallites, enhanced basicity, strong Ni-KCC-1 interaction, and encapsulation of Ni particles contributed to the enhanced catalyst stability and activity. The one-pot catalyst produced high CH4 and CO2 conversions at 92% and 88% respectively, with high H2/CO ratio, and an extended stability over 72 h at 750 °C. There was limited coke deposition, predominantly of the amorphous type, owing to its synthesis method and support morphology.