Tune and turn the pyrolysis of metal organic frameworks towards stable supported nickel catalysts for the dry reforming of methane

Dry reforming of methane (DRM) is an inimitable approach for eliminating both greenhouse gases, methane and CO₂, while producing synthesis gas which further can be converted to added-value fuels. However, the industrialization of DRM has been limited due to sintering and coking to the catalysts under the harsh reaction conditions. Here, we propose a new methodology for producing tunable supported nickel-based catalysts for DRM using metal organic frameworks (MOFs) as precursors of the catalyst components. In particular, Ni- and La-MOFs were coalesced using sonication and then calcined at different temperatures to produce catalysts with tailored Ni metal size (5–20 nm) and tuned strong metal-support interactions (SMSI). Here, the synthesis of nickel and nickel oxide nanoparticles embedded on lanthanum-based supports by controlled calcination of the MOF structures is demonstrated; the Ni supported catalysts were then used for DRM reaction. Among the developed catalysts, the catalyst produced following calcination at 500 °C (Ni-La-500) has shown stable and high CH₄ conversion rates under DRM conditions at 800 °C with negligible carbon formation at elevated gas hourly space velocities. Further, the catalytic performance of Ni-La-500 catalyst (sonicated) was compared to the physically mixed MOFs derived catalyst (Ni-La-500-PM), conventional wetness impregnated catalyst (Ni-La-500 WI), Ni-MOF derived unsupported catalyst (Ni-500), and lower Ni concentration catalyst (sonicated, 10Ni-La-500). The observed CH₄ conversion rates at 50,000 mL·g_cat^–1·h⁻¹ GHSV are 81.8, 67.9, 85.4, 34.7, and 57.9 % for Ni-La-500, Ni-La-500 PM, Ni-La-500 WI, Ni-500, and 10Ni-La-500 catalysts, respectively after 24 h of DRM reaction. With isotopic studies, it was found that the ¹⁸O exchange rate was higher in case of Ni-La-500-PM catalyst (8.1 mmol·g⁻¹) as compared to Ni-La-500 catalyst (5.5 mmol·g⁻¹). Prior interaction between MOFs, calcination temperatures, reaction conditions, and the carbon pathways during catalytic activity dictates the conversion rates and selectivity of the products. Overall, with the herein proposed approach of MOF-derived supported catalysts exceptional conversion rates and stability during the DRM reaction with nominal coking and sintering were demonstrated, solving the two major challenges faced by conventional and unsupported catalysts.