Exploring the potential of cobalt-based catalysts in the methane dry reforming for sustainable energy applications

Cobalt-based powder catalysts with different Co loadings were synthesized via wet impregnation using MgAl₂O₄ spinel as support. The catalytic properties of the solids were evaluated in the dry-reforming methane at different reaction temperatures and two CH₄:CO₂ ratios. The catalyst with higher cobalt content (13 %) presented superior performance due to increased Co⁰ species availability, confirmed by XPS analysis. Besides, this catalyst displayed remarkable resistance to carbon deposition at 550 °C and CH₄:CO₂ 1: 1 ratio. In-situ DRIFT measurements demonstrated the formation and transformation of carbonate and hydrogen carbonate species during the DRM reaction, highlighting efficient CO₂ and CH₄ activation on the catalyst surface. Based on this data, a structured catalyst was deposited on top of the FeCrAlloy monolith, which was active, stable, selective for H₂, and resistant against on/off cycles. Compared with the powder catalyst, the structured system displayed higher catalytic activity, possibly due to higher reducibility of metal species and improved heat transfer provided by the FeCrAlloy substrate. The results highlight the potential of Co-based structured catalysts for H₂ or synthesis gas production processes.