Highly dispersed nickel within mesochannels of SBA-15 for CO methanation with enhanced activity and excellent thermostability

[Display omitted] •Methanation catalyst is first prepared by surfactant-assisted impregnation method.•The surfactant can hinder the migration of metal ions during drying.•The surfactant can inhibit the aggregation of NiO during calcination.•The 10%Ni/S15(3) catalyst showed excellent catalytic activity and stability. In this work, several nickel-based SBA-15 catalysts were prepared by surfactant-assisted impregnation method and applied in CO methanation reaction. The characterization results showed that Ni species were uniformly distributed in the ordered mesoporous channels of SBA-15 by adding proper surfactants. The morphologies of the unroasted catalysts and spent catalysts after 100h stability test were also investigated. The surfactant can hinder the migration of metal ions during drying and inhibit the aggregation of NiO during calcination, which ultimately improve the nickel dispersion. Consequently, the Ni/SBA-15 catalysts prepared with surfactant-assisted impregnation method exhibited superior activity and excellent thermostability owing to the moderate interaction between nickel and support, high nickel surface area and the confinement of support. The 10%Ni/S15(3) catalyst achieved the best activity with 100% CO conversion and about 99.9% CH4 yield at 350°C, 0.3MPa and 15,000mL/g/h.