Thin-felt NiO-Al₂O₃/FeCrAl-fiber catalyst for high-throughput catalytic oxy-methane reforming to syngas

Thin-felt NiO-Al₂O₃/FeCrAl-fiber catalysts engineered from micro- to macro-scales are developed for the high-throughput catalytic oxy-methane reforming to syngas. Crystallization-driven self-assembly process is used to prepare an Al(OH)₃/FeCrAl-fiber support (15 wt% Al(OH)₃). NiO of ~ 3 wt% is then highly dispersed onto above support via incipient wetness impregnation method followed by a calcination treatment. Such catalyst achieves a high CH₄ conversion of 88.6% with 90.7%/93.2% selectivity to H₂/CO at 700 °C and a high gas hourly space velocity of 80 L g^{− 1} h^{− 1}, and is stable for at least 30 h without carbon deposit but a slight sintering. In contrast, a reference catalyst of NiO/FeCrAl-fiber shows a fast deactivation within only 6 h.