Engineering coke-resistant with metal promoted Ni/silica–zirconia catalysts for syngas production via dry reforming of methane

• Ga, La, Gd, Sr, Sm promoted Ni-catalyst dispersed over SZ31107 (5Ni/SZ) is tested. • Coke deposition is least over Ga-promoted catalyst which acquires strong metal support interaction. • 5Ni1La/SZ has intermediate level MSI seeking 42% H 2 yield ( Y H 2 ) and 65% wl. • 5Ni1Sm/SZ shows least crystallinity additionally ensuing 53% Y H 2 Sm-catalyst gives 87% Y H 2 it achieves 87% H 2 yield over 30 h time on stream at 844 °C, a WHSV of 22892 cc g⁻ 1 h⁻ 1 , and a CH 4 /CO 2 ratio of 0.667. The thorough study of promoted catalyst systems, selection of the best promoted catalyst, and optimization of reaction conditions by respond surface methodology over the best catalyst evolves the 5Ni1Sm/SZ catalyst as a high-performance catalyst for a long time on stream.