Syngas production from catalytic CO₂ reforming of CH₄ over CaFe₂O₄ supported Ni and Co catalysts: Full factorial design screening

In this study, the potential of dry reforming reaction over CaFe₂O₄ supported Ni and Co catalysts were investigated. The Co/CaFe₂O₄ and Ni/CaFe₂O₄ catalysts were synthesized using wet impregnation method by varying the metal loading from 5-15 %. The synthesized catalysts were tested in methane dry reforming reaction at atmospheric pressure and reaction temperature ranged 700-800 °C. The catalytic performance of the catalysts based on the initial screening is ranked as 5%Co/CaFe₂O₄ < 10%Co/CaFe₂O₄ < 5%Ni/CaFe₂O₄ < 10%Ni/CaFe₂O₄ according to their performance. The Ni/CaFe₂O₄ catalyst was selected for further investigation using full factorial design of experiment. The interaction effects of three factors namely metal loading (5-15 %), feed ratio (0.4-1.0), and reaction temperature (700-800 °C) were evaluated on the catalytic activity in terms of CH4 and CO2 conversion as well as H2 and CO yield. The interaction between the factors showed significant effects on the catalyst performance at metal loading, feed ratio and reaction temperature of 15 %, 1.0, and 800 °C. respectively. The 15 wt% Ni/CaFe₂O₄ was subsequently characterized by Thermogravimetric (TGA), X-ray Diffraction (XRD), Field Emission Scanning Electron Microscopy (FESEM), Energy Dispersive X-ray Spectroscopy (EDX), X-ray Photoelectron Spectroscopy (XPS), N₂-physisorption, Temperature Programmed Desorption (TPD)-NH₃, TPD-CO₂, and Fourier Transform Infra Red (FTIR) to ascertain its physiochemical properties. This study demonstrated that the CaFe₂O₄ supported Ni catalyst has a good potential to be used for syngas production via methane dry reforming.