Carbon nanofibers decorated SiC foam monoliths as the support of anti-sintering Ni catalyst for methane dry reforming

A silicon carbide (SiC) foam monolith decorated with a carbon nanofibers (CNFs) layer was employed as the catalyst support for Ni-based catalyst preparation, used for the CO2 dry reforming of methane (DRM) reaction. The loading amount of CNFs on the SiC foam monolith was 6.6 wt.%, which obviously increased the surface area of the pristine SiC foam from 4 m2/g to 24 m2/g. The prepared CNFs layer strongly attached to the pristine SiC surface and was considerably stable even after 100 h time on stream (TOS) DRM reaction. The CNFs decorated SiC composite support provided more anchorage sites for improving the dispersion of the Ni particles and enhanced the metal-support interaction compared to the pristine SiC support. Compared with other catalysts such as Ni/SiC and Ni/CNFs, the Ni/CNFs-SiC catalyst exhibited not only the highest activity but also remarkable stability during DRM reaction. The XPS and SEM-EDS results showed that the carbon deposition over the nickel surface of Ni/CNFs-SiC catalyst was much less than those of Ni/SiC and Ni/CNFs catalysts. In addition, the XRD analysis verified that almost no sintering of nickel particle was detected over the Ni/CNFs-SiC catalyst, which was prepared with CNFs-SiC composite as catalyst support, even after 100 h TOS DRM reaction at 750 °C.