• • Optimal Ni loading of 12.5% maximizes CH4 and CO2 conversions; excessive 15.0% loading causes activity loss due to Ni agglomeration and pore degradation, underscoring the need for precise metal loading in industrial catalyst formulation.
• • Promoter incorporation increases surface active oxygen species (Oβ) to ~60%–68%, enhancing CO2 adsorption/activation and reducing carbon deposition, critical for maintaining catalyst longevity in high-temperature DRM operations.
• • After 20 h DRM, Ce-promoted catalyst exhibits minimal Ni particle growth from 6.23 to 8.07 nm (Δ1.84 nm), compared to >5 nm for unmodified catalyst, demonstrating superior sintering resistance essential for extended industrial campaigns.
• • Promoter-modified catalysts show substantially reduced carbon deposition and lower carbon graphitization, directly addressing the primary deactivation mechanism in DRM and improving process economics by reducing regeneration frequency.