Surface control of Ni-Al2O3 dry reforming of methane catalyst by composition segregation

Catalyst surface control is of great importance considering that a catalytic reaction initially starts with surface atoms' interaction with reactant molecules. In the present study, we synthesized the Ni-Al2O3 dry reforming of methane (DRM) catalyst via the spray-pyrolysis-assisted evaporation-induced self-assembly (EISA) method in order to systematically investigate catalyst surface change as controlled by composition segregation. The present results showed that segregation in the Ni-Al2O3 catalyst had successfully occurred by the post-annealing process and that the segregated Ni nanoparticles were located on the catalyst surface with simultaneous reduction to metal. The size of the surface Ni nanoparticles was highly dependent on the post-annealing temperature, whereas the electronic properties did not consistently align with the trend of particle-size growth, indicating that the particle-growth mechanism underwent alterations from segregation to sintering as the temperature was increased. In other words, when the reduction temperature for metal segregation is excessively high, particlegrowth on the external catalyst surface, as induced by post-annealing, is primarily attributable to particle sintering rather than to metal segregation. This phenomenon directly results in decreased Ni surface density. The catalytic DRM reaction revealed that due to sintering, the catalytic performance did not align with the trend of Ni particle-size growth, and the conversion of CH4/CO2 was closely associated with Ni surface density. This information will offer valuable insight to future research focused on development of Ni-based catalysts for DRM reactions.