CO2 Gas Research Articles

CARBON CAPTURE, USAGE AND STORAGE

Carbon Capture, Usage and Storage – in short CCUS, is not a new term in the current industrial environment. It is being discussed widely at all industrial forums, across all countries, big or small, to control pollution to ensure a healthy and happy life for all. There have been attempts and studies over last 50 years to capture carbon dioxide from the environment to avoid pollution and control global warming scenario. Many technologies have been in use for carbon capture, across the globe, some in large scale and others confined to local areas. It is expensive but very much essential – it is a goal set by WHO/UNO/European Commission – to clean the environment off CO2 gases, use it for alternative purposes or store it for future action. According to International Energy Agency (IEA), we must capture around 100 billion tons of CO2 by 2060 to meet International Global Warming and Energy goals. It is a huge goal and is a very expensive goal to achieve. All big countries who impact the environment in a huge way through their industries shall come forward for a collaboration to prepare a robust plan, pump-in money, monitor and control the processes, to achieve the goal. There is an estimate that US emitted around 5,1 mln t of CO2 in 2019 whereas Global estimate emitted around 33 mln t. These are very huge numbers and hence Global monitoring is very essential to control emission and safe storage and disposal. It is important to understand that Carbon Capture (CC), Carbon Capture and Use (CCU) and Carbon Capture and Storage (CCS) are three different terms. CC, CCU and CCS are combinedly termed as CCUS. CC is to capture carbon from various sources – fuel gas, fossil fuels, petroleum products, flares from refineries and power plants etc. Usage of the captured carbon in the form of carbon dioxide (CO2) is CCU and this is an important long-term vision by any government to ensure it is being used meaningful to avoid negative impact on climate. CCS is storage of the captured carbon quickly so that it does not impact the environment as a greenhouse gas and at the same time, it can be used later. Another term which is frequently used is Net Zero CO2. It is defined as follows: Any CO2 released into the atmosphere from a human activity shall be balanced by an equivalent amount being removed, either by nature-based solutions (including afforestation, reforestation or other changes in land use) or technological solutions that stores CO2 captured directly or indirectly, permanently. Net Zero CO2 is very important, unless this is achieved, CCUS goal cannot be achieved to control climate change. This write-up provides an insight into the following topics:  What is CCUS?  Why is it important?  Steps to CCUS;  CAPEX and OPEX involved.

Enhancing energy efficiency in Bangladesh’s readymade garment sector: the untapped potential of LED lighting retrofits

Purpose Previous studies emphasized the substantial energy-saving potential of light emitting diode (LED) lighting systems, especially in the clothing industry. However, the specific quantification of energy conservation potential in industrial factories, particularly in Bangladesh’s readymade garment (RMG) sector, remains unexplored. The purpose of this study is to investigate the potential energy savings and efficiency improvements of lighting systems in Bangladesh’s RMG sector using LED technology. Design/methodology/approach Understanding and optimizing energy consumption is crucial in the RMG sector because this sector contributes significantly to the country’s export earnings. For this, an RMG factory was surveyed and possible lighting system retrofitting was estimated and compared. Findings The adoption of energy-efficient lighting options, particularly LED, could decrease the current lighting energy usage from 15% to 7.5% in Bangladesh. First, this study reveals, that the reduction of annual energy consumption was determined to be 18,220 kWh due to the retrofitting of the lighting system with LED tube. Second, it conducts real-time measurements to assess the suitability of in-building lighting systems, providing insights into the current scenario. Lastly, it evaluates the economic and environmental benefits of the proposed lighting system in the RMG industries. Due to the retrofitting of the lighting system, the reduction of equivalent CO2 gas emissions was found to be 119.896 tCO2. Originality/value For the first time, this study explored the potential for enhancing energy-efficient lighting system design through retrofitting in the RMG industry, with a focus on Bangladesh. By addressing these aspects, this study aims to contribute to the advancement of energy efficiency and conservation efforts in the RMG sector, ultimately fostering sustainable industrial development in Bangladesh and beyond.

Decorating carbon nanotubes with different ratios of graphene quantum dots via ultrasonication as a potential material for CO2 capture

ABSTRACT The harmful impacts of carbon dioxide (CO2) emissions are represented mainly in global warming as a major greenhouse gas, health problem issues, and pollution. As a result, there is currently worldwide interest in developing efficient adsorbents with high adsorption capacity for CO2 gas. In this work, the adsorbent nanocomposites were synthesized from different loadings of graphene quantum dots (10, 20, and 30%) with carbon nanotubes (CNTs) using the ultrasonication method. The prepared nanocomposites were characterized by XRD, HR-TEM UV-Vis, Raman, and BET, techniques to investigate their chemical and physical characteristics. The samples reveal a high surface area and porosity. The optical band gap was calculated for the nanocomposites; it decreased upon increasing the ratio of the GQDs, since the 30% GQDs/CNT show an Eg of about 1.93 eV compared to 2.1 eV for the 10% and 20% GQDs/CNTs. The samples of 20% and 30% GQDs/CNTs revealed the highest active site density; furthermore, they showed the best performance for CO2 gas capture of about 24.6 mmol. g−1 and 25 mmol. g−1, which makes these nanocomposites efficient adsorbents for CO2 emissions.

How CO2 gas accelerates water nucleation at low temperature

We conducted homogeneous nucleation experiments for dilute binary H2O–CO2 mixtures in Ar–N2 carrier gas with different CO2/H2O ratios at temperatures of 57 and 75 K and total pressures of ∼40 and 70 Pa, respectively. Direct experimental information on the number and type of molecules in the clusters and on the cluster number concentration is obtained by mass spectrometric detection of nucleating clusters that form in the uniform region of Laval expansions. Only homo-molecular water clusters are observed in the mass spectra. However, as the CO2/H2O ratio increases, a significant increase in the nucleation rate is observed. A simple kinetic model suggests that this acceleration of nucleation is due to the formation of short-lived, transient hetero-molecular H2O–CO2 dimers. Comparison with homogeneous binary nucleation of toluene–CO2 and unary nucleation of H2O shows that nucleation becomes more efficient in systems with stronger intermolecular interactions and a larger number of degrees of freedom. Such studies at the molecular level will improve our understanding of homogeneous nucleation mechanisms in atmospheric and industrial processes.

The impacts of CO2 on sandstone reservoirs in different fluid environments: insights from mantle-derived CO2 gas reservoirs in Dongying Sag, Bohai Bay Basin, China

The impacts of CO2 on sandstone reservoirs in different fluid environments: insights from mantle-derived CO2 gas reservoirs in Dongying Sag, Bohai Bay Basin, China

Effects of Al doping on structural, optical, morphological, and low-concentration CO2 gas sensing properties of ZnO nanoparticles synthesized by sol-gel method

Abstract This work examines the morphological, structural, optical, and gas-sensing characteristics of ZnO thin films doped with Al that were created by the sol-gel spin coating technique. The thin films, doped with varying aluminum concentrations (0%, 2%, and 5%), were characterized using XRD, UV-visible spectroscopy, and FE-SEM to assess their crystallinity, band gap, and surface morphology. XRD analysis confirmed the incorporation of Al into the ZnO lattice without forming secondary phases, while UV-visible spectroscopy revealed an increase in transmittance and band gap with higher Al doping. FE-SEM images showed a transition from agglomerated grains to smoother surfaces with increased Al content. Gas sensing performance was evaluated using low-concentration CO2 as the target gas. The results demonstrated that Al doping significantly enhances the CO2 sensing response, with the 5% Al-doped ZnO exhibiting the optimal sensitivity due to increased carrier concentration and improved surface interaction. These findings suggest that Al-doped ZnO thin films are promising candidates for efficient CO2 gas sensors, combining enhanced structural and optical properties with superior gas sensing capabilities.

Adsorption-absorption technique for effective CO2 capture

ABSTRACT This paper presents a study on the removal of CO2 gas from gas mixture (CO2/N2) of 14% CO2 using adsorption onto zeolite 13X in a fluidized bed at 298 K and 1 atm pressure. The effects of static bed height (5–25 cm) and rate of flow of the gas mixture (6–14 L/min) on the breakthrough time were studied. The desorption of CO2 was performed by absorbing the adsorbed CO2 molecules using NaOH solution (0.1 M). The absorption process which was accompanied with chemical reaction achieved two objectives. The first was converting CO2 gas into a valuable substance (Na2CO3) which could be used in many industries. The second was the storage of CO2 gas in what was called a chemical carrier which could emit the gas when it was needed. The effect of static bed height (5–25 cm) on the absorption process in the fluidized bed was also studied. For the adsorption process, the results showed that the breakthrough time increased with decreasing the flow rate but with increasing the static bed height. In the desorption process, the total amount of absorbed CO2 molecules was 396 mg, achieving a recovery of 90.8% at 5 cm static bed height.

Engineering Dual-Defective 0D/2D VN-CNQDs/VBi-Bi4O5Br2 S-Scheme Heterostructure for Boosting CO2 Photoreduction in Air.

The direct photocatalytic reduction of CO2 in air is the future trend of photocatalyst application. Herein, the 0D carbon nitride quantum dots with nitrogen vacancies (VN-CNQDs) and 2D bismuth-deficient Bi4O5Br2 (VBi-Bi4O5Br2) are integrated by hydrothermal method. The S-scheme heterostructure of VN-CNQDs/VBi-Bi4O5Br2 composite promotes the separation rate of photogenerated carriers and enhances the redox capacity. The dual defects provide a large number of adsorption and catalytic sites that enhance the ability to capture and reduce CO2. The synergistic effect of S-scheme heterostructure and defect engineering enables the efficiency of CO2 photoreduction to CO with VN-CNQDs/VBi-Bi4O5Br2 to reach 16.89µmolg-1h-1 in air and 55.69µmolg-1h-1 in VCO2: VAir = 3:1 condition, which is 17 and 21 times higher than that of Bi4O5Br2, respectively. The dual-defective VN-CNQDs/VBi-Bi4O5Br2 exhibits more lower energy barrier for forming *CO2, *COOH, and *CO and is easier to release CO gas. And it exhibits excellent cycling stability for photocatalytic CO2 reduction to CO. The photocatalytic reduction mechanism of CO2 to CO in the VN-CNQDs/VBi-Bi4O5Br2 S-scheme heterostructure is further analyzed. This work provides new perspectives for the design of the photocatalysts with defect engineering for efficient photoconversion at low CO2 concentrations.

Sonodynamic Cancer Therapy by Mn(I)-tricarbonyl complexes via Ultrasound-triggered CO release and ROS generation.

A novel ferrocene conjugated Mn(I)-tricarbonyl complex viz [Mn(Fc-tpy)(CO)3Br] (Mn2) where, Fc-tpy = 4'-ferrocenyl-2,2':6',2''-terpyridine was synthesized and fully characterized along with its non-ferrocene analog [Mn(Ph-tpy)(CO)3 Br] Ph-tpy = 4'-phenyl-2,2':6',2''-terpyridine (Mn1) for ultrasound (US) activated anticancer applications. The X-ray structure of Mn2 confirmed its distorted octahedral geometry. Mn1 and Mn2, for the first time, showed US-triggered release of CO and ROS generation (1O2 and •OH) in an aqueous solution from any Mn(I)-tricarbonyl complexes, indicating its potential for synergetic CO gas therapy and sonodynamic therapy. The above-mentioned in-solution chemistry was successfully translated into in vitro cellular models. These complexes showed unprecedented US-triggered toxicity against T-cell lymphoma and human breast cancer cells (IC50 for Mn2 < 1 μM) while were minimally toxic without US or against normal spleen cells. Mn2 was ca. 12 fold more anticancer active than Mn1, indicating that the ferrocene conjugation augmented the US sensitivity. The apoptotic sonotoxicity of Mn2 was due to US-promoted mitochondrial depolarization via ROS generation and CO release. The apoptosis was triggered by caspase 3 activation. This is the first report of Mn(I)-tricarbonyl-based sonosensitizers for cancer SDT. Overall, this study, for the first time, establishes the effectiveness of 3d metal carbonyls in SDT.

Synthesis of Benzoic Acids from Electrochemically Reduced CO2 Using Heterogeneous Catalysts.

A method for the synthesis of benzoic acids from aryl iodides using two of the most abundant and sustainable feedstocks, carbon dioxide (CO2) and water, is disclosed. Central to this method is an effective and selective electrochemical reduction of CO2 (eCO2RR) to CO, which mitigates unwanted dehalogenation reactions occurring when H2 is produced via the hydrogen evolution reaction (HER). In a 3-compartment set-up, CO2 was reduced to CO electrochemically by using a surface-modified silver electrode in aqueous electrolyte. The ex-situ generated CO further underwent hydroxycarbonylation of aryl iodides by MOF-supported palladium catalyst in excellent yields at room temperature. The method avoids the direct handling of hazardous CO gas and gives a wide range of benzoic acid derivatives. Both components of the tandem system can be recycled for several consecutive runs while keeping a high catalytic activity.

Improved gas sensing properties of copper-doped MoSe2 monolayers: a first-principles study on CO2 and NO2 adsorption

Abstract This paper investigates the impact of copper (Cu)-doped MoSe2 monolayer (ML) on gas sensing properties. The adsorption behaviour of CO2 and NO2 gas molecules on Cu-doped MoSe2 ML is reported and various sensing and electronic parameters such as adsorption energy, charge transfer and recovery time, are computed to delineate the adsorption characteristics and gas sensitivity. In our study, the doped Cu-atom in Se vacant MoSe2 ML shows the adsorption energies to be −1.32 eV (O-orient) and −1.72 eV (C-orient), for CO2, while for NO2, they are −0.879 eV (O-orient) and −1.06 eV (N-orient), respectively. The negative formation energy of −6.62 eV shows the electronic stability of Cu-doped MoSe2 ML and thermal stability, demonstrated by the molecular dynamics study through the Nose-Vervlet Thermostat (NVT) algorithm. Also, significant changes are observed in electronic conductivity and work function upon adsorbed Cu-MoSe2 ML. Lastly, these outcomes illustrate that Cu doping amplifies the capture ability of MoSe2 ML towards gas molecules, fostering improved electron interaction between the substrate surface and gas molecules, consequently enhancing its gas sensing ability.

Toward Modeling Continental‐Scale Inland Water Carbon Dioxide Emissions

AbstractInland waters emit significant amounts of carbon dioxide (CO2) to the atmosphere; however, the global magnitude and source distribution of inland water CO2 emissions remain uncertain. These fluxes have previously been “statistically upscaled” by independently estimating dissolved CO2 concentrations and gas exchange velocities to calculate fluxes. This scaling, while robust and defensible, has known limitations in representing carbon source limitations and spatial variability. Here, we develop and calibrate a CO2 transport model for the continental United States, simulating carbon transport and transformation in &gt;22 million hydraulically connected rivers, lakes, and reservoirs. We estimate 25% lower CO2 fluxes compared to upscaling estimates forced by the same observational calibration data. While precise CO2 source distribution estimates are limited by the resolution of model parameterizations, our model suggests that stream corridor CO2 production dominates over groundwater inputs at the continental scale. Our results further suggest that the lack of observational networks for groundwater CO2 and scalable metabolic models of aquatic CO2 production remain the most salient barriers to further coupling of our model with other Earth system components.

Genesis of an Inorganic CO2 Gas Reservoir in the Dehui–Wangfu Fault Depression, Songliao Basin, China

This study systematically examines the origins and formation mechanisms of inorganic CO2 gas reservoirs located within the Dehui–Wangfu Fault in the southeastern uplift region of the Songliao Basin. The research aims to clarify the primary sources of inorganic CO2, along with its migration and accumulation processes. The identification of the Wanjinta gas reservoir within the Dehui–Wangfu Fault Zone, abundant in inorganic CO2, has sparked significant interest in the pivotal roles of volcanism and tectonic activity in gas generation and concentration. To analyze the release characteristics of CO2, this study conducted degassing experiments on volcanic and volcaniclastic rock samples from various boreholes within the fault trap. It evaluated CO2 release behaviors and controlling factors across varying temperatures (150 °C to 600 °C) and particle sizes (20, 40, and 100 µm). The findings indicated a negative correlation between CO2 release and particle size, with a notable transition at 300 °C—marking this temperature as critical for the release of adsorbed and lattice gases. Moreover, volcaniclastic rocks exhibited higher CO2 release compared to volcanic rocks, attributable to their larger specific surface area and higher porosity. At 600 °C, the decomposition of the rock crystal structure results in substantial gas escape. These observations suggest that the inorganic CO2 in this area derives not only from mantle sources but is also influenced by crustal components. Elevated temperatures prompted by tectonic activity and magmatic intrusion facilitated the degassing of the surrounding rocks, allowing released CO2 to migrate upwards through the fracture system and accumulate in the shallow crust, ultimately forming a gas reservoir. This study enhances the understanding of volcanic rock’s roles in inorganic CO2 gas generation and migration, highlighting the fracture system’s critical controlling influence on gas transport and aggregation. The findings indicate that inorganic CO2 gas reservoirs in the Dehui–Wangfu Fault Zone primarily originate from mantle sources with a mixture of crustal gases. This discovery offers new theoretical insights and practical guidance for the exploration and development of gas reservoirs in the Songliao Basin and similar regions.

A Simple Regeneration Process Using a CO2-Switchable-Polarity Solvent for Cellulose Hydrogels.

Cellulose is one of the main components of plant cell walls, abundant on earth, and can be acquired at a low cost. Furthermore, there has been increasing interest in its use in environmentally friendly, carbon-neutral, sustainable materials. It is expected that the applications of cellulose will expand with the development of a simple processing method. In this study, we dissolved cellulose in aqueous N-butyl-N-methylpyrrolidinium hydroxide solution ([C4mpyr][OH]/H2O) and investigated the cellulose regeneration process based on changes in solubility upon application of CO2 gas. We investigated the effect of transformation of the anion chemical structure on cellulose solubility by flowing CO2 gas into [C4mpyr][OH]/H2O and conducted pH, FT-IR, and 13C NMR measurements. We observed that the changes in anion structure allowed for the modulation of cellulose solubility in [C4mpyr][OH]/H2O, thus establishing a simple and safe cellulose regeneration process. This regeneration process was also applied to enable the production of cellulose hydrogels. The hydrogel formed using this method was revealed to have higher mechanical strength than an analogous hydrogel produced using the same dissolution solvent with the addition of a cross-linker. The ability to produce cellulose-based hydrogels of different mechanical properties is expected to expand the possible applications.

CO2-assisted gasification of Patagonian rosehip bio-wastes: Kinetic modeling, analysis of ash catalytic effects, and product gas speciation

In the present study, the valorization of two rosehip wastes –husk and seed– was performed, through the CO2 gasification of biochar obtained by pyrolysis. The kinetics of gasification in a CO2 atmosphere at different partial pressures was investigated, obtaining the activation energy (E), pre-exponential factor (A), conversion function (f(α)), and reaction order with respect to the partial pressure of CO2 (x). The rosehip seed waste biochar (RSWB) yielded the following parameters: E = 302.11 kJ/mol, A = 2.18×1012 1/(s atm0.64), f(α) = 321−α−1/3−1−1; while the rosehip husk waste biochar (RHWB) results were: E = 198.60 kJ/mol, A = 2.13 × 1008 1/(s atm0.64), f(α) = 21−α1/2. The reaction order was the same in both wastes and equal to 0.64. The greater reactivity of RHWB can be attributed to the catalytic effects of the ashes contained in the biomass. To evaluate this effect, tests were conducted on rosehip husk waste ash mixtures with orthoasphaltite mineral char in proportions of 1, 5, 7, and 10 % (m/m). Thermogravimetry determined that the gasification temperature decreased up to 200 °C compared to pure char. Additionally, dry gasification of raw biomass experiments were carried out, and the evolution of gaseous products was analyzed with FTIR spectroscopy, evaluating the absorbance profiles of CO, CH4, and CH3OH, and comparing them with those obtained in a pure N2 atmosphere. The results obtained demonstrated the potential of rosehip wastes as a source in thermochemical processes for its complete valorization in a production chain with a focus on biorefinery.

Efficient low-temperature detection of CO gas by various metalated porphyrinic-Al-based MOF (Cu and Co) materials

A series of porphyrinic-Al-based metal–organic framework (MOF) nanomaterials were successfully fabricated via a simple solvothermal procedure and denoted as AlPMOF(M) (M = Cu, Co). The materials exhibited high surface areas with rectangular morphologies and the desired phases. Chemical composition studies demonstrated the presence of Cu and Co ions in the synthesized samples, while thermal studies showed the samples were stable up to 400 °C. CO gas-sensing studies revealed better CO sensing performances of both the AlPMOF(Cu) and AlPMOF(Co) gas sensors compared to the pristine sensor at room temperature. AlPMOF sensor showed responses of 1.06 and 1.05 to 10 ppm CO gas at 150 and 25ºC, respectively, with no selectivity to CO gas at 25ºC. AlPMOF (Co) sensor revealed responses of 1.11 and 1.06 to 10 ppm CO gas at 200 and 25ºC, respectively, with selectivity to CO gas at 25ºC. Also, AlPMOF (Cu) sensor revealed responses of 1.12 and 1.07 to 10 ppm CO gas at 150 and 25ºC, respectively, with selectivity to CO gas at 25ºC. In addition, the sensing mechanism and enhanced response to CO gas were elucidated. These findings demonstrate the capability of these novel sensing materials for CO gas sensing at low temperatures.

Direct reduction of CO2 to carbon material on liquid cathode in molten salts

This study presents a novel method for the direct reduction of CO2 to produce carbon materials on a liquid cathode in high-temperature molten salts. CO2 gases were introduced into a Sn-Li liquid alloy, and they were subsequently reduced to solid carbons by the Li in the alloy. Unreacted CO2 gases were absorbed as carbonate ions (CO32−) in molten salts containing oxide ions (O2−). Subsequently, these carbonate ions were electrochemically reduced to solid carbons on the liquid cathode surface. Consequently, the current density was five times higher than that achieved using the conventional method without bubbling CO2 into the liquid cathode. The enhanced current density can be attributed to the combined thermochemical reduction of CO2 by Li and the electrochemical reduction of CO32−. This combination was realized for the first time at a relatively positive potential range, where pure Li or Ca cannot be deposited, leading to the carbon yield of over 90 % relative to CO2 feed reached. The resulting carbons contained a trace amount of Sn, which could be removed by washing after milling. These results show the potential for efficient and sustainable carbon capture and conversion technologies using liquid cathodes in high-temperature molten salts for CO2 reduction.

Experimental study on the internal pressure evolution of large-format LiFePO4 battery during thermal runaway

The safety problems of lithium-ion batteries, such as fire and explosion, have become the main issues constraining the rapid development of electrochemical energy storage. This paper proposes a new method to obtain the internal pressure and gas components of battery under adiabatic condition. Subsequently, the internal pressure evolution of a fully charged 300 Ah LiFePO4 (LFP) cell during thermal runaway (TR) are analyzed. At the temperature of safety venting (SV), the internal peak pressure recorded is 412 kPa and the gas release of H2 and CO are 35.2 % and 23.7 %, respectively. Basing on the analysis, the gas release temperature calculated by internal pressure is about 5 K lower than self-generated heat temperature. Before SV, the electrolyte volatilization and gas releasing are decoupled, and the gas release is about 0.009 mol. The internal pressure evolution of battery can be divided into three stages. At stage C, the gas release which cause SV account for 43.97 % of the gas volume and the reactions releasing H2 and CO gas are the prime chemical reason for SV. These results are of great significance to the setting of early warning system and the emergency response to TR.

Pd-Catalyzed highly regioselective migratory hydroesterification of internal olefins with formates

Double bonds of internal olefins can be efficiently migrated to the terminal carbons and regioselectively hydroesterified with formates in the presence of Pd(OAc)2 and 1,2-DTBPMB under mild reaction conditions, providing a wide variety of corresponding linear carboxylic esters bearing various functional groups in good yields and >20:1 linear/branch ratios. The reaction is optionally simple and does not need to use CO gas and acid co-catalysts.

Suspension-washcoat optimization for preparing copper-manganese oxide structured catalyst towards flue gas CO purification

Structured catalysts play significant role in nowaday environmental industry. The copper-manganese oxide (Cu-Mn) is a low cost and efficient catalyst for CO purification from flue gas, for which a robust preparation regarding stabilized suspension and washcoat process is still lacked. This work addressed this challenge by constructing the catalyst suspension by introducing absorbent polymer (SAP), polyvinyl alcohol (PVA), and nano-silica sol (SiO2-NA). The effects of the dosage of SAP, PVA, and SiO2-NA on suspension properties including viscosity, water-retention capacity and stability were systematically studied. The combined effect of the three additives regarding electrostatic-sterical stability and regionalized coating is demonstrated to avoids the destruction of connection between SiO2-NA and Cu-Mn due to the thermal stress during the drying process. After calcination, SiO2-NA is efficiently utilized, evenly distributed and tightly bonded to Cu-Mn catalyst, rendering strongly-attached, crack-free and compact washcoated layer. The optimized structured catalyst shows appreciable balance of loading (up to 182kg/m3) and strength (powder shedding rate <1wt%) without blockage. The potential of practical application was verified by CO purification from realistic iron-ore sintering flue gas with catalytic efficiency of above 90% for 240h. These findings indicated a promising strategy to design Cu-Mn structured catalysts efficient for industrial use.