Manufacture of highly loaded Ni catalysts by carbonization–oxidation–reduction for dry reforming of methane

The manufacture of high metal loading catalysts is of great interest in heterogeneous catalysis; however, there are challenges in the construction of the catalytic structure, including particle size, dispersion, and accessibility. Herein, we fabricate a high Ni loading catalyst by the carbonization–oxidation–reduction (COR) strategy for low-temperature dry reforming of methane. The carbon coating obtained by carbonizing organic ligands protects Ni nanoparticles from agglomeration and sintering. Subsequent oxidation–reduction treatment sacrifices carbon and causes Ni redispersion, resulting in dual particle size distribution. The sacrifice of carbon enhances the metal–support interaction and the resistance of metal sintering. 30% Ni/MCF-COR exhibits higher and more stable catalytic activity at relatively low reaction temperature compared with 30% Ni/MCF-H2. COR pretreatment is promising in the manufacture of high metal loading catalysts for the conversion of greenhouse gasses.