A potential
nickel-supported infiltrate mesoporous silica-aluminosilicate
(Ni/SAS) catalyst was developed for improving hydrogen production
through methane decomposition reaction. Infiltrate mesoporous silica-aluminosilicate
supports with different Si/Al ratios (25, 50, and 100) were synthesized
through a sol–gel method, then nickel metal was loaded on the
support using an incipient impregnation method. All SAS(x) supports revealed a bimodal mesoporous structure with pore sizes
at 2.7 and 3.9 nm. The aluminum favorably incorporated into the silica
framework in the tetrahedral-coordinated position as [AlO4]5– to form an aluminosilicate framework in the
structure of SAS(50). The active nickel area of Ni/SAS(x) catalysts was 1.30–2.27 times higher than that of the Ni/MCM-41
catalyst. Using the Ni/SAS(x) catalyst in the cracking
reaction gave a higher H2 yield than using a Ni-supported
silica catalyst. In particular, the H2 yield of the Ni/SAS(50)
catalyst was 1.45, 1.11, and 1.29 times higher than that of the Ni/MCM-41
catalyst at 500, 550, and 600 °C, respectively. This performance
could be attributed to a promotional effect of the infiltrate aluminosilicate
framework as well as the moderate surface acidity, which enhanced
the Ni dispersion and interaction between Ni and the SAS support,
resulting in the multi-walled carbon nanotube formation via a tip-growth
mechanism. Consequently, the active surface of the Ni/SAS(50) catalyst
remained constant throughout the methane decomposition reaction.