Chemical Engineering Journal, Vol.357, 435-446, 2019
Preparation and characterization of Ni/Al2O3 catalyst coatings on FeCrAl-loy plates used in a catalytic channel reactor with in-situ spatial profiling to study CO2 methanation
The catalyzed CO2 methanation is an important step in the Power-to-Gas process, and obtaining accurate kinetic data for this fast and exothermic reaction is challenging. An optically accessible catalytic plate reactor with spatially-resolved measurement techniques provides the opportunity to collect high quality kinetic data for this heterogeneous system by gathering catalyst surface temperature and gas composition profiles along the reactor axis. This reactor requires a well-coated catalyst plate with an uniform and known catalyst mass distribution. Three different methods (brush, spin and frame coating) for the deposition of ready-made Ni/Al2O3 catalysts onto FeCrAl-loy plates were examined. To enhance the adhesion of the catalyst, a thermal pre-treatment of the plate and the use of an alumina-based binder were needed. A homogeneous coating was achieved with frame coating, using a slurry with a total solid (i.e., catalyst and binder) to liquid ratio of 0.25:5 g(soli)(ds)/ml(solution), catalyst to binder mass ratio of 9:1 and a mixed water to isopropanol volume ratio 1:4. High resolution profilometry confirmed the homogeneity of the produced coating with a constant catalyst mass distribution of 1.5 +/- 0.1 mg cat mm(-1). Gas composition and catalyst surface temperature profiles were acquired for the CO2 methanation at 355 degrees C, 1 bar with total gas hourly space velocities of 68.5 and 103 l(N) h(-1) g(cat)(-1). Approximately 60 points per gas species per experiment were collected, which is a huge advantage compared to typical steady-state integral reactor with end-of-pipe measurement resulting in a single data point.
Keywords:Ni/Al2O3 wash-coating;Spatially-resolved measurement;CO2 methanation;Kinetic measurements;IR thermography