The Properties of Individual Carbon Residuals and Their Influence on The Deactivation of Ni-CaO-ZrO2 Catalysts in CH4 Dry Reforming

Ni-CaO-ZrO2 catalysts with different properties were prepared and tested for CO2 reforming of methane. The catalysts were characterized by means of transmission electron microscopy, thermogravimetric analysis, Raman spectroscopy, X-ray photoelectron spectroscopy, and X-ray diffraction to reveal their distinct properties and carbon deposition behaviors in the reforming reaction. It was found that the catalyst prepared by a coprecipitation method and ageing by heating to reflux exhibited a nanocrystalline structure with strong metal-support interaction, which was responsible for both high activity and stability, but it also exhibited the highest carbon formation rate among the tested catalysts. This result suggests that catalyst deactivation might not necessarily correlate with the amount of formed carbon, and the individual properties of carbon residuals could play a more decisive role. Carbon residuals on different catalysts were identified as amorphous carbon, encapsulating carbon, whisker carbon, and graphite, which had different influence on the deactivation. On the surface of the most active and stable catalyst, the carbon species mainly consisted of amorphous and whisker carbon, suggesting that the formation of such carbon species does not necessarily lead to catalyst deactivation. In contrast, the deactivation was found to be closely related to the formation of encapsulating carbon and graphite, which could coat the catalyst surface. The accumulation of different carbon residuals was proven to follow a formation-diffusion/elimination scenario, which was significantly influenced by the Ni particle size and Ni-ZrO2 interactions.