CH₄ is a powerful greenhouse gas that is thought to be one of the main causes of global warming. The catalytic conversion of methane in the presence of oxygen into hydrogen-rich syngas, known as the partial oxidation of methane (POM), is highly appealing for environmental and synthetic concerns. In search of a cheap catalytic system, the Ni-supported MgO-based (5Ni/MgO) catalyst and the promotional supplement of 1–3 wt.% Sr over 5Ni/MgO are investigated for the POM reaction. Catalysts are characterized by N₂ sorption isotherm analysis, X-ray diffraction spectroscopy, Raman spectroscopy, temperature-programmed desorption techniques, and thermogravimetry. Increasing the loading of strontium over Ni/MgO induced a strong interaction of NiO with the support, pronouncedly. In the presence of oxygen during the POM, the moderate-level interaction of NiO with the support grows markedly. Overall, at a 600 °C reaction temperature, the 5Ni2Sr/MgO catalyst shows 72% CH₄ conversion (~67% H₂ yield) at 14,400 mL/h/g_cat GHSV and ~86% CH₄ conversion (84% H₂ yield) at 3600 mL/h/g_cat GHSV. Achieving a higher activity towards the POM over cheap Ni, Sr, and MgO-based catalysts might draw the attention of environmentalists and industrialists as a low-cost and high-yield system.

The development of cost-effective non-noble metal catalysts for the partial oxidation of methane (POM) remains a key strategy for producing hydrogen-rich syngas while mitigating greenhouse gas emissions. In this study, cobalt-supported alumina (Co/Al₂O₃) catalysts were prepared using 5 wt.% of Co and calcined at 600, 700, and 800 °C. Subsequently, Co/Al₂O₃ catalysts were promoted with 10 wt.% Mg, Si, Ti, and Zr at the optimized calcination temperature. The catalysts were systematically characterized by FT-IR, XRD, N₂ physisorption, H₂-TPR, and XPS analyses. Catalytic activity tests for POM of CH₄ were conducted at 600 °C (CH₄/O₂ = 2 and GHSV = 14,400 mL g⁻¹ h⁻¹). Catalysts calcined at 700 °C (5Co/Al_700) exhibited the highest activity among unpromoted samples, with CH₄ conversion of 43.9% and H₂ yield of 41.8%. The superior performance was attributed to its high surface area and the abundance of reducible Co³⁺ species, generating a greater number of Co⁰ active sites. XPS results confirmed the structural stability of γ-Al₂O₃ and preserved Co–Al interactions across calcination temperatures, while promoters mainly modulated Co dispersion and redox accessibility. Among the promoted catalysts, the activity order followed: 5Co/10ZrAl > 5Co/10MgAl> unpromoted-5Co/Al_700 > 5Co/10SiAl > 5Co/10TiAl. Si and Ti promoted catalysts acquired less concentration of active sites and less activity as well. The concentration of reducible species as well as initial activity towards POM are comparable over Zr and Mg-promoted catalysts. However, earlier one has a higher edge of reducibility and sustained constant activity over time in a stream study. The Zr-promoted catalyst exhibited superior reducibility and remarkable stability, achieving 47.3% CH₄ conversion and 44.4% H₂ yield sustained over 300 min time-on-stream. TEM analysis of spent 5Co/10ZrAl indicated that Zr promotion suppressed graphitic carbon formation.