Ni-SiO₂ catalysts for the carbon dioxide reforming of methane: varying support properties by flame spray pyrolysis.

Silica particles were prepared by flame spray pyrolysis (FSP) as a support for nickel catalysts. The impact of precursor feed rate (3, 5 and 7 mL/min) during FSP on the silica characteristics and the ensuing effect on catalytic performance for the carbon dioxide, or dry, reforming of methane (DRM) was probed. Increasing the precursor feed rate: (i) progressively lowered the silica surface area from ≈340 m2/g to ≈240 m2/g; (ii) altered the silanol groups on the silica surface; and (iii) introduced residual carbon-based surface species to the sample at the highest feed rate. The variations in silica properties altered the (5 wt %) nickel deposit characteristics which in turn impacted on the DRM reaction. As the silica surface area increased, the nickel dispersion increased which improved catalyst performance. The residual carbon-based species also appeared to improve nickel dispersion, and in turn catalyst activity, although not to the same extent as the change in silica surface area. The findings illustrate both the importance of silica support characteristics on the catalytic performance of nickel for the DRM reaction and the capacity for using FSP to control these characteristics.