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For the production of CH4 from CO hydrogenation, a hybrid foam with high catalytic activity and strong magnetic bonding ability was fabricated by electrospraying and co-sintering Nd-doped NiAl catalytic nanoparticles and NdFeB magnetic nanoparticles over a Fe foam. When the NdNiAl nanoparticles were uniformly distributed over a NdFeB nanoparticles support, they exhibited exceedingly high catalytic activity, selective conversion and stable adhesion. In particular, bimodal NdNiAl–NdFeB hybrid nanoparticles (with a ratio of 85.0 to 15.0 wt%) immobilized on Fe foam exhibited a high CO to CH4 conversion rate, with a TOF value of 1.1 s−1 and a CH4 selectivity value of 77.1% at a specific temperature of 260.0 °C. This improved catalytic behavior was attributed to the enhanced uniform dispersion of NdNiAl nanoparticles over a NdFeB nanoparticles support. At the same time, the NdFeB nanoparticles had high hydrogen absorptivity, which helped adjacent NdNiAl nanoparticles activated with CO to be hydrogenated and produce CH4.

rsc advances

Bimodal NdNiAl and NdFeB hybrid catalytic and magnetic nanoparticles laminated on Fe foam: catalytic conversion of CO + 3H<sub>2</sub> to CH<sub>4</sub>

Bimodal NdNiAl and NdFeB hybrid catalytic and magnetic nanoparticles laminated on Fe foam: catalytic conversion of CO + 3H2 to CH4

Bimodal NdNiAl and NdFeB hybrid catalytic and magnetic nanoparticles laminated on Fe foam: catalytic conversion of CO + 3H₂ to CH₄