The catalytic oxidation of toluene over Pd-based FeCrAl wire mesh monolithic catalysts prepared by electroless plating method

The electroless plating method was used for the preparation of Pd-based FeCrAl wire mesh monolithic catalysts without alumina interlayer film. The 0.3–0.4 wt.% Pd/FeCrAl prepared catalysts calcined at suitable temperature of 800 °C showed excellent low-temperature catalytic oxidation activity and good catalytic stability in the 70 h durability test, which might be contributed to the formation of a molten appearance for PdO active particles in 0.1–1 μm size scale on the surface of the catalyst. Such a molten appearance can bring about the increase of catalytic activity as well as the prevention of the catalyst from deactivation in toluene oxidation reaction.

► Pd/FeCrAl catalysts without interlayer film are prepared by electroless plating.
► The catalyst exhibits good low-temperature toluene oxidation activity.
► The catalyst exhibits good catalytic stability in toluene complete oxidation.
► Formation of the molten state for PdO active particles is the key for catalyst.