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Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming

[Image: see text] Megapores with spherical-like cells connected through windows and high porosities make up catalyst supports in the form of ceramic foams. These characteristics provide significant benefits for catalytic processes that are limited by mass or heat transport. This study focuses on the...

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Autores principales: Yeetsorn, Rungsima, Tungkamani, Sabaithip, Maiket, Yaowaret
Formato: Online Artículo Texto
Lenguaje:English
Publicado: American Chemical Society 2022
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8829922/
https://www.ncbi.nlm.nih.gov/pubmed/35155913
http://dx.doi.org/10.1021/acsomega.1c05841
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author Yeetsorn, Rungsima
Tungkamani, Sabaithip
Maiket, Yaowaret
author_facet Yeetsorn, Rungsima
Tungkamani, Sabaithip
Maiket, Yaowaret
author_sort Yeetsorn, Rungsima
collection PubMed
description [Image: see text] Megapores with spherical-like cells connected through windows and high porosities make up catalyst supports in the form of ceramic foams. These characteristics provide significant benefits for catalytic processes that are limited by mass or heat transport. This study focuses on the manufacture of ceramic foam using a polymeric sponge replica process and polymer foams as a template for catalyst supports, which are industrial waste from the packaging sector. To make ceramic foam catalysts, they were dipped in a catalyst solution, followed by a breakdown stage and a sintering process. Experiments focused on determinants that affect the desired characteristics of ceramic foams, such as the types of polymer foams that affect foam morphology, the rheology of catalyst solution that affects catalyst dispersion, and the polymer decomposition rate that affects catalytic performance during dry reforming of the methane process. The cell architectures of polyurethane and polyvinyl alcohol foams are attractive for catalyst support preparation because they have 98–99% porosity and typical cell sizes of 200 and 50 μm, respectively. The polyurethane performance was superior to the performance of polyvinyl alcohol in terms of higher porosity and better catalytic-solution absorption offering high catalyst active areas. The catalyst prepared from concentrated 10 wt % Ni/Al(2)O(3)–MgO (10NAM) slurry had the highest surface area (59.18 m(2)/g) and the highest metal oxide dispersion (5.65%). These results are relevant to the flow behavior of catalyst slurry which plays a key role in coating the catalyst gel on the polymer template. The thermal decomposition rate used to remove the polymer template from the catalyst structure is proportional to the ceramic foam structure (catalyst support structure). The slow decomposition rate bent and fractured foam-cell struts more than the faster rate. On the other hand, achieving good catalyst dispersion on catalyst supports necessitated a high sintering rate. When sintering was adjusted at a high sintering rate, the metal–particle dispersion was relatively high, around 7.44%, and the surface area of ceramic foam catalysts was 64.61 m(2)/g. Finally, the catalytic behavior toward hydrogen production through the dry reforming of methane using a fixed-bed reactor was evaluated under certain operating conditions.
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spelling pubmed-88299222022-02-11 Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming Yeetsorn, Rungsima Tungkamani, Sabaithip Maiket, Yaowaret ACS Omega [Image: see text] Megapores with spherical-like cells connected through windows and high porosities make up catalyst supports in the form of ceramic foams. These characteristics provide significant benefits for catalytic processes that are limited by mass or heat transport. This study focuses on the manufacture of ceramic foam using a polymeric sponge replica process and polymer foams as a template for catalyst supports, which are industrial waste from the packaging sector. To make ceramic foam catalysts, they were dipped in a catalyst solution, followed by a breakdown stage and a sintering process. Experiments focused on determinants that affect the desired characteristics of ceramic foams, such as the types of polymer foams that affect foam morphology, the rheology of catalyst solution that affects catalyst dispersion, and the polymer decomposition rate that affects catalytic performance during dry reforming of the methane process. The cell architectures of polyurethane and polyvinyl alcohol foams are attractive for catalyst support preparation because they have 98–99% porosity and typical cell sizes of 200 and 50 μm, respectively. The polyurethane performance was superior to the performance of polyvinyl alcohol in terms of higher porosity and better catalytic-solution absorption offering high catalyst active areas. The catalyst prepared from concentrated 10 wt % Ni/Al(2)O(3)–MgO (10NAM) slurry had the highest surface area (59.18 m(2)/g) and the highest metal oxide dispersion (5.65%). These results are relevant to the flow behavior of catalyst slurry which plays a key role in coating the catalyst gel on the polymer template. The thermal decomposition rate used to remove the polymer template from the catalyst structure is proportional to the ceramic foam structure (catalyst support structure). The slow decomposition rate bent and fractured foam-cell struts more than the faster rate. On the other hand, achieving good catalyst dispersion on catalyst supports necessitated a high sintering rate. When sintering was adjusted at a high sintering rate, the metal–particle dispersion was relatively high, around 7.44%, and the surface area of ceramic foam catalysts was 64.61 m(2)/g. Finally, the catalytic behavior toward hydrogen production through the dry reforming of methane using a fixed-bed reactor was evaluated under certain operating conditions. American Chemical Society 2022-01-27 /pmc/articles/PMC8829922/ /pubmed/35155913 http://dx.doi.org/10.1021/acsomega.1c05841 Text en © 2022 The Authors. Published by American Chemical Society https://creativecommons.org/licenses/by-nc-nd/4.0/Permits non-commercial access and re-use, provided that author attribution and integrity are maintained; but does not permit creation of adaptations or other derivative works (https://creativecommons.org/licenses/by-nc-nd/4.0/).
spellingShingle Yeetsorn, Rungsima
Tungkamani, Sabaithip
Maiket, Yaowaret
Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming
title Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming
title_full Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming
title_fullStr Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming
title_full_unstemmed Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming
title_short Fabrication of a Ceramic Foam Catalyst Using Polymer Foam Scrap via the Replica Technique for Dry Reforming
title_sort fabrication of a ceramic foam catalyst using polymer foam scrap via the replica technique for dry reforming
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC8829922/
https://www.ncbi.nlm.nih.gov/pubmed/35155913
http://dx.doi.org/10.1021/acsomega.1c05841
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