The Development Of Metal-based Honeycomb Catalyst Carrier

Aluminum ethyloxide were fabricated by direct reaction method in applying the aluminum powder and ethanol. Alumina sol was obtained via hydrolysis using Al(OEt)3 as a precursor under proper condition. After concentration, the dip-coating method were applied to fabricated an alumina coating on the surface of the metal based honeycomb substrates. The metallic honeycomb mentioned above were produced with the aid of a self-designed equipment. It is reveal that the preparation course of aluminum ethyloxide were dramatically influenced by the factors such as water, steam and catalyst. The influence of these factors on alumina sol preparation course were also investigated. Through adding PEG in alumina sol, the structure of the pores were charged via the alteration of the stacking state of the crystals. Ba(NO3)2 were chosen as a thermal stabilizer in order to retard the V -alumina phase transition into a - alumina in high temperature. The experiment reveal that Ba(NO3)2 as thermal stabilizer is fail to work because of the reaction between the metal substrates and Ba(NO3)2 in the course of heat treatment, this kind of reaction making bad influence to catalyst substrates.Alumina wash-coat were fabricated via dip-coating technology, which is a simple, efficient and low cost way to fabricate a good quality film with a sol. The thickness of the wash-coat dipped were influenced by three main factors: the viscosity of the sol, the withdraw speed and the number of dippings. A proper value of the three factors is the key to obtain a good wash-coat on the surface of the chosen metal substrate.The thermal shock test were conducted between 0~600C in order to judge the viability of the wash-coat, 60 cycles were performed and the weight lost were measured. It is reveal that the weight lost after 60 cycles is smaller than 15%.The metallic honeycomb fabricated by the corrugation method via a self-designed equipment. The Fe-Ni strip or reticular net strip were used as the substrate material. The strip or net strip was first corrugated into ripple strip with a plane strip so as to form the honeycomb structure. The honeycomb was cleaned by a chemical wash, which forms a clean surface ready to coat.As a summary, the process of fabrication of the alumina coated metallic honeycomb have been investigated in this thesis. The metallic honeycomb was fabricated by the corrugated method via a self-designed equipment. The alumina wash-coat were formed via a sol obtained by hydrolysis of the aluminium ethyloxide which were prepared via direct reaction of aluminum powder and the ethanol. Further investigation into the viability of the coated metallic honeycomb as the catalytic substrate were under consideration.