Hierarchically structured nanospherical fibrous silica-supported bimetallic catalysts: An enhanced performance in methane decomposition

Hydrogen production by methane catalytic decomposition is a promising method that also allows the formation of valuable carbon nanomaterials which can be utilized in transportation fuels, chemical synthesis, and fuel cell technology. In this study, bimetallic 3d transition metal (Ni, Fe, Co) catalysts supported on spherical mesoporous nanofibrous silica (KCC1) were successfully synthesized using a hydrothermal method followed by sono co-impregnation. The catalysts were evaluated for their performance in the catalytic decomposition of methane. Comprehensive characterization of the catalysts was conducted utilizing XRD, FTIR, SEM, TEM, STEM, XPS, H₂-TPR, and BET techniques. XRD and TEM analyses confirmed the formation of Ni–Fe, Ni–Co, and Co–Fe bimetallic alloys on the nanofibrous silica without compromising its dendrimeric hierarchical structure. STEM HAADF imaging revealed a uniform dispersion of bimetallic nanoparticles within the spherical fibrous framework. Catalytic tests demonstrated that all bimetallic catalysts showed high stability and activity for methane cracking at 700 °C over 180 min of time on stream (TOS). Among them, Fe-based catalysts Ni–Fe/KCC1 and Co–Fe/KCC1 achieved the highest hydrogen yields of 80% and 60%, respectively. Methane conversion was 1.56 and 2.23 times higher in Ni–Fe/KCC1 compared to Co–Fe/KCC1 and Ni–Co/KCC1, respectively. Post-reaction characterization of the spent catalysts was performed using XRD, Raman spectroscopy, SEM, TEM, and TGA. XRD and Raman spectroscopy were used to evaluate the degree of graphitization and crystallinity in the carbon nanotubes (CNTs) produced on the catalysts, enabling a correlation with the catalyst properties. TEM examination was used to investigate the structural morphology and growth methods of the CNTs, including tip or base growth and chain-like or parallel-wall types. TGA results revealed that all bimetallic catalysts exhibited no amorphous carbon during methane cracking reaction.