Supported nanocomposite catalysts for high-temperature partial oxidation of methane

In order to utilize the vast potential of nanoparticles for industrial catalysis, it is necessary to develop methods to stabilize these particles at realistic technical conditions and to formulate nanoparticle-based catalysts in a way that facilitates handling and reduces health and safety concerns. We have previously demonstrated that metal nanoparticles can be efficiently stabilized by embedding them into a high-temperature stable nanocomposite structure. Building onto these results, we report here on the next step towards a simple, hierarchically structured catalyst via supporting platinum barium-hexaaluminate (Pt-BHA) nanocomposites onto a range of different conventional and novel support structures (monoliths, foams, and felts). The catalysts were characterized via SEM, TEM, XRD, porosimetry, chemisorption, and reactive tests in catalytic partial oxidation of methane to synthesis gas (CPOM), and compared to conventionally prepared Pt-catalysts. In particular silica felt supported Pt-BHA showed excellent activity and selectivity combined with good stability and very low noble metal requirement at the demanding high-temperature conditions of short-contact time CPOM. Overall, we see great potential for these supported nanocomposite catalysts for use in demanding environments, such as high-temperature, high-throughput conditions in fuel processing and similar energy-related applications.