Wet chemical synthesis route was used to synthesis nickel ferrite (NiFe2O4) nanoparticle. Later on the synthesized NiFe2O4 were supported on the surface of three traditional supports such as Al2O3, MgO and TiO2 to get NiFe2O4/Al2O3, NiFe2O4/TiO2 and NiFe2O4/MgO catalysts. The activity profile of each catalyst was evaluated in a fixed-bed reactor for direct methane decomposition at 800 °C. For both fresh and spent catalysts, many characterization techniques have been employed mainly XRD, FESEM, HRTEM, Raman spectroscopy, TGA, and nitrogen adsorption-desorption isotherm. X-ray powder diffraction studies revealed that all synthesized catalysts have a cubic spinel crystal structure. The XRD confirm the presence of NiFe2O4 particles in the component of fresh NiFe2O4/MgO, NiFe2O4/TiO2 and NiFe2O4/Al2O3 catalysts. Temperature Program Reduction (TPR) unveiled the presence of Ni oxides and Fe oxides by displaying reduction peaks in their respective temperature regions. The N2 adsorption-desorption isotherms of the fresh all catalysts reveal that these catalysts have a mesoporous structure. Activity data concluded NiFe2O4/MgO to be the most active catalysts among the tested catalysts methane conversion magnitude of 41.13 % and H2 formation rate of 84.40 × 10−5 mol H2 g−1 min−1. On the other hand, the H2 formation rate drastically declined and very poor activity of both NiFe2O4/TiO2 and NiFe2O4/Al2O3 catalysts was observed in the current work. XRD patterns, FESEM images and TGA analysis of spent NiFe2O4/MgO catalyst shown the filamentous carbon formation which secondarily confirm its higher activity, while its absence in catalysts of NiFe2O4/TiO2 and NiFe2O4/Al2O3. TGA analysis of the carbon deposited on the NiFe2O4/MgO catalyst showed that the amount of carbon was approximately 64 wt%. It was suggested that the formation of nickel-iron carbide revealed by XRD studies of spent catalysts may be the factor related to their poor activity while discussing the structure-activity relationship. Likewise, the higher degree of dispersion related to NiFe2O4/MgO as displayed by XRD, FESEM and TPR investigations, played a vital role in accelerating the rate of hydrogen formation.
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