Applying Taguchi robust design to the optimization of the synthesis parameters of nanocrystalline Cr-free Fe–Al–Cu catalyst for high temperature water gas shift reaction

Abstract

Nanocrystalline Cr-free Fe–Al–Cu catalysts with high surface area and mesoporous structure was prepared by coprecipitation method and employed in high temperature water gas shift reaction. Several parameters such as pH, aging temperature and aging time were optimized by the Taguchi method of experimental design. The sample prepared under optimized conditions showed a high surface area of 208m2g−1, pore size of 3.76nm and theoretical particle size of 5.47nm after calcination at 400°C for 4h. This catalyst illustrated the highest CO conversion compared to other prepared catalysts. These results confirmed that the Taguchi method is an effective method of determining the optimum parameters in preparation process of high temperature water gas shift catalyst. Moreover, the effect of calcination temperature, GHSV and steam/gas ratio on the catalytic performance of optimized Fe–Al–Cu catalyst was investigated.