Binder effect on CeO2-based technical catalyst performance: insights and implications

Abstract

Cerium oxide has earned recognition as a valuable support material in heterogeneous catalysis due to its exceptional catalytic properties. Ensuring the mechanical stability of CeO2-based technical catalysts is crucial for reliable industrial performance. This study reports two primary approaches for enhancing the mechanical resistance of these catalysts. Firstly, thermal treatment was explored, applying various calcination temperatures and heating rates, which highlighted the balance between mechanical strength and porosity in catalyst supports. Secondly, the influence of inorganic binders ―boehmite, bentonite, and kaolinite― on the physicochemical properties and catalytic performance of CeO2-based supports in the context of CO2 methanation was systematically evaluated. Binder-modified CeO2-based technical supports (with a CeO2-to-binder ratio of 10:1) were fabricated, impregnated with nickel salts, characterized using N2-physisorption, compression assays, XRD, TGA, SEM-EDX, and H2-TPR, and their activity in the methanation of CO2 was assessed. Bentonite demonstrated remarkable strength enhancement, doubling the mechanical resistance compared to the pure CeO2 support. However, employing clay-altered supports as catalysts led to unfavorable results for application in practical cases. Boehmite emerged as a highly promising binder, demonstrating exceptional chemical and mechanical stability and minimal disruption to the activity of the catalyst in CO2 methanation thus establishing its practical suitability for catalyst development. This research highlights the nuanced influence of different binders on catalyst performance, providing valuable insights into the design and optimization of CeO2-based catalysts for applied catalytic technologies.