Process Optimization for Syngas Production from the Dry Reforming of Methane over 5Ni+3Sr/10Zr+Al Catalyst Using Multiple Response Surface Methodology

5Ni+3Sr/10Zr+Al catalyst is synthesized using the impregnation method, characterized, and tested for dry reforming of methane. The influence of reaction temperature, feed ratio (CO2/CH4), and gas hour space velocity are examined using multiple response surface methodology through three factors in, a four-level central composite design. Second and higher-order regression models are applied to evaluate the interaction between the process parameters and responses. The results indicate that the reaction temperature is the most influential followed by the space velocity, while the feed ratio has a weak effect. The optimum values that maximize each of the response variables are found to be the reaction temperature at 746 C-degrees, the space velocity of 12 000 ccg(-1)h(-1), and the feed ratio of 0.958. Under these conditions, the predicted CH4 and CO2 conversions are 86.83% and 92.27%, respectively. While the H-2/CO ratio is 1.02. On the other hand, the experimental results match the predicted ones when the optimum predicted operating conditions are used for the process. A weight loss of <16% is obtained on the spent catalyst after 86 h on stream. This is attributed to the highly basic and oxidative nature of the ZrO2 co-supported catalyst and indicates the suitability of the developed catalyst.