In this work, the Ni-based catalysts (10wt.%Ni/Al2O3-MgO and 10wt.%Ni/MgO) were synthesized by sol-gel method. Each catalyst was prepared as catalyst pellets and catalyst-coated plate, stainless steel plate coated with catalyst. The catalyst-coated plates were fabricated using spray coating. The dry methane reforming (DMR) performances of catalyst-coated plate were investigated and compared with DMR performances of catalyst pellets. As the mass transfer was improved, the methane consumption rate per gram of catalyst coated onto metal plate was ten times greater than those of catalyst pellets approximately. The carbon deposition was also significantly prevented when the catalyst was constructed as a thin-film layer on the plate under our developing condition. Therefore, this catalyst-coated plate can be further developed for multichannel reactor

A novel dual Ni-based catalytic process (DCP) to control the H₂/CO ratio of 2 in the syngas product within one step at temperature <700 °C was created and constructed. With the sequence of the catalysts located in the single reactor, the endothermic combined steam and CO₂ reforming of methane (CSCRM) reaction and the exothermic ultra-high-temperature water–gas shift (UHT-WGS) reaction work continuously. During the process, the H₂/CO ratio is raised suddenly at UHT-WGS after the syngas is produced from CSCRM, and CSCRM utilizes the heat released from UHT-WGS. Due to these features, DCP is more compact, enhances energy efficiency, and thus decreases the capital cost compared to reformers connecting with shift reactors. To prove this propose, the DCP tests were done in a fixed-bed reactor under various conditions (temperature = 500, 550, and 600 °C; the feed mixture (CH₄, CO₂, H₂O, and N₂) with H₂O/(CH₄ + CO₂) ratio = 0.33, 0.53, and 0.67). According to the highest CH₄ conversion (around 65%) with carbon tolerance, the recommended conditions for producing syngas with the H₂/CO ratio of 2 as a feedstock of Fischer–Tropsch synthesis include the temperature of 600 °C and the H₂O/(CH₄ + CO₂) ratio of 0.53.

High temperature water gas shift (HT-WGS) is an important catalytic process connected with reforming process in hydrogen production. Ni/CeO₂-Al₂O₃ (or Al₂O₃) catalysts were studied in this work on the effect of catalyst preparation method toward the physicochemical properties and the HT-WGS activity. Ni/CeO₂-Al₂O₃ were prepared by sol-gel and impregnation methods whereas Ni/Al₂O₃ was prepared by impregnation method. The catalyst samples were characterized by XRD, H₂-TPR and H₂-TPD techniques. The catalytic activities of HT-WGS catalysts was demonstrated at 550°C, GHSV of 2x10⁵ mLh^-1gcat^-1and steam-to-CO ratio of 3. Nickel was detected as a nickel aluminate phase in the calcined catalyst. Ni strongly interacted with support in the calcined catalyst prepared by sol-gel method. The strong metal-support interaction can be resisted by preparing catalyst via impregnation and CeO₂ can promote the H₂O dissociation in HT-WGS mechanism. The highest metal dispersion, largest metal surface area and greatest HT-WGS activity were consequently achieved by Ni/CeO₂-Al₂O₃ prepared from impregnation method.