Development of shaped NiCoMg/γ-Al2O3 catalyst with commercial support for CO2 reforming of CH4

•Spherical CO2 reforming of CH4 catalyst was made by impregnating commercial γ-Al2O3 balls.•Procedures of impregnating Ni, Co, and Mg solutions and calcination influenced the catalyst performance.•Multistep and alternating impregnation and calcination resulted in acceptable physical and performance properties.•At 750 °C and 110 L gcat−1 h−1, the average CH4 conversion of the spherical catalyst during 180 h TOS is 60%.

Spherical NiCo bimetallic catalysts for CO2 reforming of CH4 were prepared by direct impregnation of Mg, Ni and Co onto the BASF CSS-350 alumina balls (BASF Catalysts LLC). The effects of the sequence of impregnation and calcination and the concentration of impregnation solutions on the catalyst properties and performances were studied. ICP-MS (Inductively Coupled Plasma Mass Spectrometry) analysis, BET (Brunauer-Emmett-Teller) analysis, XRD (X-ray Diffraction), compressive strength test, and XANES (X-ray Absorption Near-Edge Structure) spectroscopy and TEM (Transition Electron Microscopy) were conducted to characterize the physical and chemical properties of the catalysts. The catalysts were tested for CO2 reforming of CH4 reaction under the conditions of 0.10 g catalyst loading, 750 °C, ambient pressure, GHSV = 100,000 mL g cat−1 h−1, CH4/CO2/N2 = 1/1/1 and different lengths of time-on stream (TOS). The spherical catalyst made with multiple steps of impregnation in more dilute Mg, Ni, Co solutions each followed by calcination showed extraordinary activity and stability for 180 h TOS.

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