Abstract
Structured catalysts based on hydrotalcite-derived coatings on open-cell metallic foams combine tailored basic/acidic sites, relatively high specific surface area and/or metal dispersion of the coating as well as low pressure drop and enhanced heat and mass transfer of the 3D metallic support. The properties of the resulting structured catalysts depend on the coating procedure. We have proposed the electro-base generation method for in situ and fast precipitation of Ni/Al and Rh/Mg/Al hydrotalcite-type materials on FeCrAlloy foams, which after calcination at high temperature give rise to structured catalysts for syngas (CO + H2) production through Steam Reforming and Catalytic Partial Oxidation of CH4. The fundamental understanding of the electrochemical-chemical reactions relevant for the electrodeposition and the influence of electrosynthesis parameters on the properties of the as-deposited coatings as well the resulting structured catalysts and, hence, on their catalytic performance, were summarized.
Highlights
Open-cell metallic foams are promising supports to develop the so-called structured catalysts for process intensification [1,2]
Metallic foams have been coated by the same procedures used to coat their honeycomb monoliths counterparts: (i) the deposition of catalyst slurries [7,8,9,10]; (ii) the deposition of catalyst supports followed by impregnation of the active phase [11,12,13]; and (iii) the in situ synthesis of the catalyst [14,15,16,17]
This paper provides an overview of the electrodeposition of HT materials onto FeCrAlloy open-cell foams
Summary
Open-cell metallic foams are promising supports to develop the so-called structured catalysts for process intensification [1,2]. In the deep study performed for the preparation of structured catalysts by electrodeposition of HT compounds we realized that the coating of complex metallic foam structures with such HT catalyst precursors faced several issues to reach a target catalytic film that included the metal nitrate concentration. Despite the formation of a thin coating, the structured catalyst exhibited catalytic performances comparable with those of a Ni-containing commercial catalyst under industrial-type conditions, i.e., S/C = 1.7, P = 20 bar, τ = 4 s, and Toven = 900 ◦ C (Figure 5c) These results confirmed the advantages of using structured catalysts based on metallic foams such as enhanced heat transfer and increased effectiveness factor, to a better utilization of the catalyst
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