Guefoams (guest-containing foams) as novel heterogeneous catalysts: Preparation, characterization and proof-of-concept testing for CO2 methanation

The preparation and use of Guefoams as heterogeneous catalyst is reported. The Guefoam catalyst consists of an open-pore Al-Si foam that accommodates a freely mobile guest phase (Ni/CeO2/Al2O3 particles) in its cavities, with neither a physical nor a chemical matrix-guest bond. A eutectic Al-12Si alloy was used as a low-melting matrix precursor to prevent thermal sintering of the active phase during liquid metal infiltration. CO2 methanation was chosen as the reaction test. The activity and CH4 selectivity (close to 100%) achieved with the Guefoam catalyst were similar to those obtained with a packed bed of the same active phase particles, but with the advantages of a structured reactor such as robustness and ease of handling. The thermal conductivity of the Guefoam catalyst is significantly improved with regard to the packed bed of active phase particles, which reduces the temperature gradients in the catalytic reactor, as demonstrated by computational fluid dynamic modelling. Since the permeability of the Guefoam catalyst is 2.7 times that of the packed bed, the pressure drop caused by the passage of a fluid through the novel material is reduced, resulting in a significantly higher catalytic performance index than the packed bed.

Automated summary

The preparation and use of Guefoams as heterogeneous catalyst is reported. The Guefoam catalyst, consisting of an open-pore Al-Si foam and a freely mobile guest phase, shows similar activity and selectivity to a packed bed of the same active phase particles, but with the advantages of a structured reactor. The Guefoam catalyst also exhibits improved thermal conductivity and permeability compared to the packed bed.