Exploring the performance of Co/Al2O3–ZrO2 nanocatalysts developed through the thermal evaporation method in dry reforming of methane

Abstract This study aimed to investigate the performance of the thin layer nanostructures of Co/Al2O3–ZrO2 in the dry reforming of methane (DRM) in a microchannel reactor. The nanostructures were prepared via utilizing the thermal evaporation method. Reactor tests were carried out at various coating times of 2, 3, and 4 min and temperatures of 700, 750, and 800 °C with a feed flow rate of 10 ml/min and a 1:1:8 ratio of helium, carbon dioxide, and methane. Also, grazing incidence X-ray diffraction (GIXRD), field emission scanning electron microscopy (FESEM), and energy-dispersive X-ray (EDX) were used to identify catalyst features. According to the obtained results, the highest percentage of conversion in all samples was observed at 800 °C. The results of the reactor tests also revealed that the activity of catalyst layers highly depends on coating time. The findings demonstrated that raising deposition time improves the distribution of particle size and catalyst loading. Considering the nanostructure of Co/Al2O3–ZrO2, the sample undergoing 4 min coating time yielded the highest amount of primary methane conversion (89.3 %), primary carbon dioxide conversion (92.4 %), and H2/CO molar ratio (0.91). The stability test of the catalyst layers for 28 h at the optimum condition (P = 1 atm, T = 800 °C, t = 4 min deposition time, CH4/CO2 = 1, and GHSV = 48,000 mL g−1 h−1) showed that the catalysts prepared by this method had a good stability.