LAUSR

Developing cost-effective nonprecious active metal-based catalysts for syngas (H2/CO) production via the dry reforming of methane (DRM) for industrial applications has remained a challenge. Herein, we utilized a facile and scalable mechanochemical method to develop Ba-promoted (1–5 wt %) zirconia and yttria–zirconia-supported Ni-based DRM catalysts. BET surface area and porosity measurements, infrared, ultraviolet–visible, and Raman spectroscopy, transmission electron microscopy, and temperature-programmed cyclic (reduction–oxidation–reduction) experiments were performed to characterize and elucidate the catalytic performance of the synthesized materials. Among different catalysts tested, the inferior catalytic performance of 5Ni/Zr was attributed to the unstable monoclinic ZrO2 support and weakly interacting NiO species whereas the 5Ni/YZr system performed better because of the stable cubic ZrO2 phase and stronger metal–support interaction. It is established that the addition of Ba to the catalysts improves the oxygen-endowing capacity and stabilization of the cubic ZrO2 and BaZrO3 phases. Among the Ba-promoted catalysts, owing to the optimal active metal particle size and excess ionic CO32– species, the 5Ni4Ba/YZr catalyst demonstrated a high, stable H2 yield (i.e., 79% with a 0.94 H2/CO ratio) for up to 7 h of time on stream. The 5Ni4Ba/YZr catalyst had the highest H2 formation rate, 1.14 mol g–1 h–1 and lowest apparent activation energy, 20.07 kJ/mol, among all zirconia-supported Ni catalyst systems.