Effect of Ga-Promoted on Ni/Zr + Al2O3 Catalysts for Enhanced CO2 Reforming and Process Optimization

In this study, zirconia-modified alumina support (S) was used to investigate Ga-promoted Ni catalysts for dry reforming of methane (DRM). The catalysts (Ni + (0–3) wt% Ga/S) were prepared using the wet impregnation method and calcined at 700 °C for 3 h. The inclusion of Ga enhanced the surface area, basicity, and metal-support interaction of the Ni-Ga/S catalysts. Smaller Ni particles containing Ga were seen in the TEM. The most active and stable catalyst was Ni + 2.0 Ga/S, having a conversion of 35% CO 2 and 28% CH 4 at 600 °C and displaying less (17%) carbon deposition. Furthermore, the DRM process was optimized by a mathematical model. The model determined the optimal conditions as follows: temperature (800 °C), gas flow rate (GHSV—30,000 ml h −1 gcat −1 ), and methane to carbon dioxide ratio (1:1). The model predicts CH 4 and CO 2 conversions of 76.76% and 82.0%, respectively, and an H 2 /CO ratio of 1.02, compared to experimental results showing CH 4 conversion at 74.56%, CO 2 conversion at 83.25%, and an H 2 /CO ratio of 1.01. The model demonstrates excellent agreement with the experimental observations, exhibiting less than 3% error. Graphical Abstract