Developing Ni-based honeycomb-type catalysts using different binary oxide-supported species for synergistically enhanced CO2 methanation activity

[Display omitted] •Honeycomb-type Ni-based catalysts with different oxide supports were synthesized.•The catalytic activity and stability tests for CO2 methanation were performed.•The factors influencing catalytic activity and stability were investigated and discussed.•10 wt% Ni/CeO2 honeycomb catalyst showed the best CO2 methanation activity (80%).•The optimum process variables for CO2 conversion were proposed. Honeycomb-type structured nickel-based catalysts based on the binary oxides TiO2, Al2O3, Y2O3, and CeO2 as supporters of CO2 methanation were successfully synthesized under various conditions by using different coating solutions and characterized. The prepared catalysts were further tested, and their CO2 methanation activity, stability, and selectivity were compared under different operating conditions at varying temperatures. The results revealed better CO2 methanation with an isopropanol-coated liquid than with distilled water, Si binder, and Ludox. Among the synthesized catalysts, the 10 wt% Ni/CeO2 honeycomb-type catalyst showed the highest CO2 methanation catalytic activity, stability, and selectivity, with a CO2 conversion efficiency of more than 80% during testing at an optimal temperature of 298 °C, space velocity of 743 h−1, and catalyst loading of 134 g/L. The optimum parameters and CO2 conversion efficiency were verified and reconfirmed through response surface analysis. The 10 wt% Ni/CeO2 catalyst is a promising catalyst with excellent potential for application in CO2 methanation.