A nickel catalyst supported on medium surface area beta-SiC was successfully used in the partial oxidation of methane into synthesis gas. The high thermal conductivity of the SiC support prevented the formation of hot spots on the catalyst surface at the start of the reaction in contrast to what is observed on a traditional alumina-based insulated catalyst. Carbon nanofilament growth did not occur on the SiC-based catalyst. The combination of hot spot and carbon nanofilament formation led to the complete destruction of the body shape of the alumina-based catalyst after reaction whereas the SiC-based catalyst still retained its macroscopic shape. (C) 2004 Elsevier B.V. All rights reserved.