Nickel Foam Supported Catalysts With Aluminum-Oxide Bonding
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Solution Overview
Problem
Existing methods for producing metal foam supported catalysts face challenges with poor adhesion of catalytically active coatings, leading to detachment under mechanical stress and reduced catalyst service life, and require complex equipment or hazardous reagents.
Innovation Solution
A process involving the application of an aluminum-containing powder to a nickel foam, followed by thermal treatment to form an alloy in the upper layers, oxidative treatment to create an aluminum oxide layer, and application of a catalytically active layer, ensuring strong adhesion and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a catalytically active coating is applied to a metal foam support body, then the catalyst becomes active for chemical transformations, but the coating detaches under mechanical stress due to poor adhesion
Solution Approach 1:
The patent applies an aluminum-containing intermediate layer to the metal foam support body before applying the catalytically active coating. This preliminary action creates a stable bonding interface that prevents subsequent detachment of the catalytic layer under mechanical stress, thereby resolving the adhesion problem while maintaining catalyst service life
Solution Approach 2:
The aluminum-containing layer acts as an intermediary between the metal foam support body and the catalytically active coating. This intermediate layer provides a stable bonding interface that ensures strong adhesion of the catalytic coating to the support body, preventing detachment during operation
2Ease of manufacture
If sol-gel processes are used to coat metal foams, then the catalytic coating can be applied, but special equipment and hazardous reagents are required
Solution Approach 1:
The patent employs a simple dip-coating method with aluminum-containing powder and binder solution that can be performed with basic laboratory equipment rather than specialized sol-gel apparatus. This approach uses readily available, non-hazardous materials that can be handled with standard safety precautions, eliminating the need for complex equipment and hazardous reagents
3Reliability
If atomic layer deposition is used to produce stable oxide layers, then the coupling between metal foam surface and oxidic coating becomes stable, but the apparatus becomes extremely complex
Solution Approach 1:
The patent uses an aluminum-containing intermediate layer that can be applied by simple dip-coating to create a stable bonding interface between the metal foam support body and the catalytically active coating. This intermediary approach achieves reliable coupling stability without requiring the extremely complex apparatus needed for atomic layer deposition
Solution Approach 2:
The patent replaces the complex atomic layer deposition process with a simple dip-coating method using aluminum-containing powder and binder solution. This substitution maintains the essential function of creating a stable intermediate layer while eliminating the need for extremely complex deposition apparatus
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process produces a catalyst with excellent adhesion and mechanical stability, suitable for large-scale production, reducing the risk of detachment and enhancing durability in industrial reactors.
Implementation Method 1
treating metal foam body AX thermally to achieve alloy formation between metal foam body A and aluminum-containing powder MP
Implementation Method 2
oxidatively treating metal foam body B so as to obtain metal foam body C
Data Source
AI summary
The invention relates to methods for producing supported catalysts, comprising: providing a metal foam element A made of nickel; applying an aluminum-containing powder MP to metal foam element A, such that metal foam element AX is obtained; thermally treating metal foam element AX in order to form an alloy between metal foam element A and the aluminum-containing powder MP, such that metal foam element B is obtained; oxidatively treating metal foam element B, such that metal foam element C is obtained; and applying a catalytically active layer, comprising at least one carrier oxide and at least one catalytically active component, to at least one part of the surface of metal foam element C, such that a supported catalyst is obtained. The invention also relates to the supported catalysts obtained according to the method, and to the use thereof in chemical transformations.