III International Conference

PP-III-81NEW TECHNIQUE FOR DEPOSITION OF METAL OXIDE CATALYSTS ONMETAL SUPPORTSPodyacheva O.Yu., Shikina N.V., Ismagilov Z.R., Kosarev V.F. 1 , Mishanin S.V. 2Boreskov Institute of Catalysis SB RAS, Novosibirsk, Russia1 Institute of Theoretical and Applied Mechanics, Novosibirsk, Russia2 Russian Federal Nuclear Center VNIIEF, Sarov, RussiaE-mail: pod@catalysis.ruMetal supported catalysts are very promising to use in high temperature catalyticprocesses where high heat transfer is required or in car converters. Recently, the applicationof metal supported catalysts as a part of integrated separator for methane reforming in hightemperature fuel cells was proposed. In this case, catalytic coatings and the separator itself areexposed to severe conditions, i.e. aggressive media composed of wet hydrogen, carbondioxide and electrolyte vapor. The deposition of catalytic coatings exhibiting high protectiveand adhesive properties requires the use of new or modification of known techniques. Thespraying techniques may give unique possibility to solve these problems [1]. In this paper theadvantages of the use of cold gas dynamic spraying are demonstrated for the synthesis ofmetal oxide catalysts supported on metal foils.A gun with supersonic jet working at ambient temperature [2, 3] was applied fordeposition of catalytic coatings on flat and corrugated thin (0.1-0.2 mm) metal foils. Aluminacoatings having different microstructure were sprayed on metal foils. Different activecomponents were introduced into the coatings via wetness impregnation. The procedure of thedeposition of Al x O y coatings with BET area in the range of 10-40 m 2 /g and pore volume0.05-0.2 cm 3 /g on metal foils was worked out. The optimum composition of Al x O y layer wasdefined depending on adhesive properties of the coatings examined by SEM and thermalcycling experiments (Fig. 1). The activity of Pd, Pd-Mn, Cu-Cr, Mn catalysts introduced intooptimum coatings on metal foils was tested in methane oxidation reaction. The Pd and Pd-Mncatalysts demonstrated the highest activity, Fig. 2, as well as stable operation at 900 o C.The prospects of cold gas dynamic technique was demonstrated for fabrication of pilotscale Pd-containing sample on corrugated foil of 500 mm length, Fig. 3. It was found that thepreparation method developed allows deposition of a uniform coating along the full lengthand introduction of up to 10 g of Pd per square meter of the foil. The pilot sample of thecatalyst demonstrated high activity in methane combustion process and adhesive properties.622