Efficient catalyst by a sequential melt infiltration method to achieve a high loading of supported nickel nanoparticles for compact reformer

This work provides a new synthesis method of Ni/Al2O3 catalyst with well-dispersed active nanoparticles (7.5 nm) and high metal content (45 wt%) for efficient and stable H2 generation at compact reformer. [Display omitted] •The compact reformer with Ni nanocatalyst was developed for distributed H2 generation.•Highly dispersed Ni(45wt%)/Al2O3 was synthesized using sequential melt infiltration.•The catalyst showed high H2 productivity (20 L·gcat−1·h−1) in SMR reaction.•1 Nm3·h−1 H2 was produced successfully by the compact reformer with the catalyst. The development of high-performance Ni catalysts including the formation and stabilization of active Ni nanoparticles with high surface areas by increasing their metal dispersion at the high metal loading have been major issues in the design of a compact reformer for hydrogen production. Herein, we first report a facile method based on the sequential melt infiltration process for creating highly dispersed Ni nanoparticles (~7.5 nm) incorporated into alumina support (Ni/Al2O3) with high Ni load (45 wt%). They showed much higher hydrogen productivity and reaction rate than that of the incipient wet-impregnated Ni catalyst and commercial Ni catalyst as well as good thermal stability in steam-methane reforming under harsh conditions.