Process and catalyst improvements for the dry reforming of methane

Catalyst and process improvement strategies for dry reforming of methane (DRM) are shown by enhancing the performance of an existing Ni/Al2O3 catalyst and adding oxygen to the feed. Alumina-supported Ni-Co catalyst, Ni/Co molar ratio = 3, was synthesized and calcined at 500 and 850 degrees C to take advantage of the possible strong metal-support interactions. The freshly reduced catalysts contained Ni-Co alloys. Higher CH4 and CO2 conver-sions, H2 and CO yields and H2/CO ratio during DRM and oxidative dry reforming of methane (ODRM) were achieved at 600 and 750 degrees C and two space-velocities for Ni3Co-500 due to a higher effective dispersion of 4.9 %. Significant carbon formation and activity loss occurred during DRM. Increasing the reaction temperature and/or with O2 co-feed increased the CH4 conversion. The outlet concentrations were stable, and carbon formed was significantly less. Changes in the crystallite size and near-surface alloy composition in the spent catalyst were detected.