Hydrothermal deposition as a novel method for the preparation of Co-Mn mixed oxide catalysts supported on stainless steel meshes: application to VOC oxidation

Synthesis and Optimization of Foam Copper-Based CoMnOx@Co3O4/CF Catalyst: Achieving Efficient Catalytic Oxidation of Paraxylene

This study successfully developed a foam copper (CF)-based CoMnOx@Co3O4/CF composite catalyst, achieving efficient thermal catalytic oxidation of paraxylene through multifactor optimization of synthesis conditions. At a Co:Mn molar ratio of 2:1 and a calcination temperature of 450 °C, the catalyst exhibited outstanding catalytic performance, with a T90 temperature as low as 246 °C, significantly lower than that of catalysts synthesized under other conditions. Additionally, BET, XPS, Raman, EPR, and H2-TPR test results indicate that the catalyst possesses a high specific surface area, abundant oxygen vacancies, a distribution of multivalent Co and Mn species, and a lower hydrogen reduction temperature, all of which contribute to the high catalytic activity of CoMnOx@Co3O4/CF. Furthermore, in situ DRIFTS confirmed that the oxidation of paraxylene on CoMnOx@Co3O4/CF follows the Mars-Van Krevelen (MvK) mechanism. The proposed reaction pathway begins with the oxidation of the methyl group on paraxylene, followed by the opening of the benzene ring and further oxidation to CO2 and H2O. The innovative structural design and excellent catalytic performance of this catalyst provide new insights and solutions for the industrial treatment of VOCs.

Nickel-Copper Oxide Catalysts Deposited on Stainless Steel Meshes by Plasma Jet Sputtering: Comparison with Granular Analogues and Synergistic Effect in VOC Oxidation

A novel method for the preparation of Ni-Cu oxide catalysts—deposition on stainless steel meshes using hollow cathode plasma jet sputtering—was studied. This method allows the preparation of thin oxide films. Consequently, the whole volume of the active phase is readily accessible for the reactants and can be employed in the catalytic reaction due to the negligible effect of internal diffusion. As a result, the activity of our sputtered catalyst was seven times higher in ethanol oxidation and 61 times higher in toluene oxidation than that of the corresponding granular catalyst. Moreover, due to stainless steel meshes used as a catalyst support, the pressure drop across the catalyst bed was lower. Finally, the catalytic activity of the sputtered Ni-Cu oxide catalyst with Ni:Cu molar ratio of 1:1 in ethanol oxidation was 1.7 times higher than that of the commercial EnviCat® VOC-1544 catalyst, while the amount of the active phase in the catalyst bed was 139 times lower. The outstanding performance of the Ni0.5Cu0.5 catalyst was ascribed to the synergistic effect between the copper and nickel components.

Platinum Nanoparticles Immobilized on Electrospun Membranes for Catalytic Oxidation of Volatile Organic Compounds

Structured catalytic membranes with high porosity and a low pressure drop are particularly suitable for industrial processes carried out at high space velocities. One of these processes is the catalytic total oxidation of volatile organic compounds, which is an economically feasible and environmentally friendly way of emission abatement. Noble metal catalysts are typically preferred due to high activity and stability. In this paper, the preparation of a thermally stable polybenzimidazole electrospun membrane, which can be used as a support for a platinum catalyst applicable in the total oxidation of volatile organic compounds, is reported for the first time. In contrast to commercial pelletized catalysts, high porosity of the membrane allowed for easy accessibility of the platinum active sites to the reactants and the catalytic bed exhibited a low pressure drop. We have shown that the preparation conditions can be tuned in order to obtain catalysts with a desired platinum particle size. In the gas-phase oxidation of ethanol, acetone, and toluene, the catalysts with Pt particle sizes 2.1 nm and 26 nm exhibited a lower catalytic activity than that with a Pt particle size of 12 nm. Catalysts with a Pt particle size of 2.1 nm and 12 nm were prepared by equilibrium adsorption, and the higher catalytic activity of the latter catalyst was ascribed to more reactive adsorbed oxygen species on larger Pt nanoparticles. On the other hand, the catalyst with a Pt particle size of 26 nm was prepared by a solvent evaporation method and contained less active polycrystalline platinum. Last but not least, the catalyst containing only 0.08 wt.% of platinum achieved high conversion (90%) of all the model volatile organic compounds at moderate temperatures (lower than 335 °C), which is important for reducing the costs of the abatement technology.

Non-thermal plasma synthesis of supported Cu-Mn-Ce mixed oxide catalyst towards highly improved catalytic performance for volatile organic compound oxidation

Compared with that of the transition metal mixed oxide pellet catalyst, the catalytic activity of the supported mixed oxide catalyst was significantly reduced, which was limited in practical industrial applications. In this work, supported Cu-Mn-Ce mixed oxide catalysts were prepared by non-thermal plasma. Catalyst characterization result demonstrated that plasma treatment could promote the proportion of oxygen vacancy and enhance the adsorptive strength of VOCs on the surface of catalyst. Meanwhile, plasma treatment process exerted a slight influence on the pore structure and morphological property of the catalyst. Consequently, CMC/SiO₂-P exhibited much higher catalytic activity than CMC/SiO₂ prepared by the incipient wetness impregnation method for the catalytic oxidation of toluene and n-hexane. Among the catalysts prepared, the 15%CMC/SiO₂-P catalyst even exhibited a high catalytic activity comparable to that of the supported noble metal catalyst for the oxidation of the inert hexane. The T₉₈ of toluene and n-hexane over 15%CMC/SiO₂-P was 260 and 280°C under the conditions of VOC concentration at 1000 ppm and WHSV at 20,000 mL·g^-1·h^-1, respectively. This work provided a novel method for the preparation of the supported transition metal mixed oxide catalyst.

Stainless steel catalyst for air pollution control: structure, properties, and activity

With the awakening of environmental awareness, the importance of air quality to human health and the proper functioning of social mechanisms is becoming increasingly prominent. The low cost and high efficiency of catalytic technique makes it a natural choice for achieving deep air purification. Stainless steel alloys have demonstrated their full potential for application in a variety of catalytic fields. The diversity of 3D networks or fibrous structures increases the turbulence within the heterogeneous catalysis, balance the temperature distribution in the reaction bed and, in combination with a highly thermally conductive skeleton, avoid agglomeration and deactivation of the active components; corrosion resistance and thermal stability are adapted to highly endothermic/exothermic or corrosive reaction environments; oxide layers formed by bulk transition metals activated by thermal treatment or etching can significantly alter the physico-chemical properties between the substrate and active species, further improving the stability of stainless steel catalysts; suitable electronic conductivity can be applied to the electrothermal catalysis, which is expected to provide guidance for the reduction of intermittent emission exhausts and the storage of renewable energy. The current applications of stainless steel as catalyst or support in the air purification have covered soot particle capture and combustion, catalytic oxidation of VOCs, SCR, and air sterilization. This paper summarizes several preparation methods and presents the relationships between the preparation process and the activity, and reviews its application and the current status of research in atmospheric environmental management, proposing the advantages and challenges of the stainless steel-based catalysts.

Modification of Cobalt Oxide Electrochemically Deposited on Stainless Steel Meshes with Co-Mn Thin Films Prepared by Magnetron Sputtering: Effect of Preparation Method and Application to Ethanol Oxidation

Magnetron sputtering is an advantageous method for preparing catalysts supported on stainless steel meshes. Such catalysts are particularly suitable for processes carried out at high space velocities. One of these is the catalytic total oxidation of volatile organic compounds (VOC), economically feasible and environmentally friendly method of VOC abatement. The reactive radio frequency (RF) magnetron sputtering of Mn and Co + Mn mixtures in an oxidation Ar + O2 atmosphere was applied to form additional thin oxide coatings on cobalt oxide layers prepared by electrochemical deposition and heating on stainless steel meshes. Time of the RF magnetron sputtering was changed to obtain MnOx and CoMnOx coatings of various thickness (0.1–0.3 µm). The properties of the supported CoOx-MnOx and CoOx-CoMnOx catalysts were characterized by scanning electron microscopy (SEM), powder X-ray diffraction (XRD), temperature programmed reduction (H2-TPR), Fourier-transform infrared (FTIR) and Raman spectroscopy, and X-ray photoelectron spectroscopy (XPS). The catalytic activity was investigated in the deep oxidation of ethanol, which was employed as a model VOC. According to the specific activities (amount of ethanol converted per unit mass of metal oxides per hour), the performance of CoOx-MnOx catalysts was higher than that of CoOx-CoMnOx ones. The catalysts with the smallest layer thickness (0.1 µm) showed the highest catalytic activity. Compared to the commercial pelletized Co-Mn-Al mixed oxide catalyst, the sputtered catalysts exhibited considerably higher (23–87 times) catalytic activity despite the more than 360–570 times lower content of the Co and Mn active components in the catalytic bed.