Catalytic combustion of residual methane on alumina monoliths and open cell foams coated with Pd/Co3O4

•Al2O3 monolith 100 cpsi and Al2O3 open cell foams 30/45 ppi coated with 3% Pd/Co3O4.•Pressure drop and volumetric heat transfer coefficients determined.•At low WHSV the 30 ppi foam reaches full methane conversion below 400 °C.•Good performance associated with higher Nusselt and hv of the coated foams.

The reactivity of a catalytic layer consisting of 3 wt.% of Pd/Co3O4 over an alumina monolith (100 cpsi, diameter 0.9 cm, length 3 cm) and two alumina open cell foams (30 and 45 ppi, diameter 0.9 cm, length 3 cm) was investigated in the oxidation of residual methane in lean conditions. The ceramic structures were coated via solution combustion synthesis (Co3O4) and wetness impregnation (Pd). The catalytic reactivity of the catalysts coated on the structured supports was assessed in a gas mixture containing 0.5 or 1 vol.% of methane at different weight hourly space velocities (WHSV, 30 and 60 NL h−1 gcat−1). Moreover, the prepared structured catalysts were characterized by measuring the pressure drop and determining the volumetric heat transfer coefficients. Both the WHSV and the characteristics of the support influenced the catalytic activity. In general, open cell foams coated with Pd/Co3O4 show superior catalytic activity than the coated monolith.

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