Developing cost-effective
nonprecious active metal-based catalysts for syngas (H
2
/CO) production via the dry reforming of methane (DRM) for industrial
applications has remained a challenge. Herein, we utilized a facile
and scalable mechanochemical method to develop Ba-promoted (1–5
wt %) zirconia and yttria–zirconia-supported Ni-based DRM catalysts.
BET surface area and porosity measurements, infrared, ultraviolet–visible,
and Raman spectroscopy, transmission electron microscopy, and temperature-programmed
cyclic (reduction–oxidation–reduction) experiments were
performed to characterize and elucidate the catalytic performance
of the synthesized materials. Among different catalysts tested, the
inferior catalytic performance of 5Ni/Zr was attributed to the unstable
monoclinic ZrO
2
support and weakly interacting NiO species
whereas the 5Ni/YZr system performed better because of the stable
cubic ZrO
2
phase and stronger metal–support interaction.
It is established that the addition of Ba to the catalysts improves
the oxygen-endowing capacity and stabilization of the cubic ZrO
2
and BaZrO
3
phases. Among the Ba-promoted catalysts,
owing to the optimal active metal particle size and excess ionic CO
3
2–
species, the 5Ni4Ba/YZr catalyst demonstrated
a high, stable H
2
yield (i.e., 79% with a 0.94 H
2
/CO ratio) for up to 7 h of time on stream. The 5Ni4Ba/YZr catalyst
had the highest H
2
formation rate, 1.14 mol g
–1
h
–1
and lowest apparent activation energy, 20.07
kJ/mol, among all zirconia-supported Ni catalyst systems.