Towards the scaling up of monolith- and foam-structured catalysts via in-situ combustion deposition for energetic applications

Monoliths and foams have received growing attention as catalyst supports in both academic research and industrial applications due to their interesting specific properties (high geometric surface area, low pressure drops, high mass and heat transfer properties). Structured catalysts can operate at high space velocity, achieving a good contact between gas phase and surface reactions. All these characteristics are highly desirable for both exothermic (methanation reaction) and endothermic reactions (reforming processes) [1]. The solution combustion synthesis (SCS) method is a suitable procedure to deposit uniform, thin and high-strength catalytic layers on ceramic monoliths and foams [2,3]. In this work, the catalytic phase was in-situ deposited by the SCS on commercial cordierite monoliths (400-500 cpsi) and alumina foams (20,30,40 ppi). The activity and stability results were investigated towards Steam Reforming (SR) and Oxy-Steam Reforming (OSR) of different fuels (CH4, biogas, n-dodecane) and CO2 methanation reaction. Then, the catalyst scale-up was investigated to evaluate the goodness and the reproducibility of the coating method.