Abstract
Structured catalysts play key roles in many industries with the advantages of low pressure drop and efficient mass transfer. The copper-manganese oxide (CuMnOx) as a cost-effective catalyst has been widely applied in gas purification, but still lack efficient structured catalyst due to the challenge in controlling its slurry and coating quality. In this work, this challenge was addressed by introducing the water-retaining agent (WRA) into slurry with sophisticatedly designed conditions. The effects of the type and dosage of WRA, pH value, and temperature on slurry properties including viscosity, stability, and water-retention were systematically studied, and the slurry property-coating quality relationship was correlated. The preferred slurry and coated layer could be segregated into sub-millimeter-sized water-retaining regions where catalyst and binder particles were well dispersed and connected. After slow release of water and organic during drying and calcination, the CuMnOx structured catalyst with uniform, defect-free and dense coating was obtained, showing high loading (>160 kg/m3), great mechanical strength (powder shedding rate < 1 wt%), and no blockage for practical use. The robustness of the structured catalysts was validated by a scale-up preparation of 2 m3 volume amount for CO purification from real ore-sintering flue gas in a steel plant, which achieved the CO catalytic efficiency maintaining over 90 % for more than 1440 h. This work showcases an efficient strategy for structured catalyst preparation and expands the gas purification application of the industrially-favored CuMnOx.
Published Version
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