Papers by Author: M. Filipa Ribeiro

Abstract: Reticulated cordierite foams produced by a direct foaming method were successfully washcoated with platinum-based zeolite catalysts. For comparison purposes, commercial cordierite monoliths were also washcoated. The effect of the structural properties on the fluid dynamics and catalytic behaviour for the toluene combustion were evaluated. Foam supports revealed highest performances, in terms of conversion into CO2, when compared to conventional honeycomb monoliths. The experimental results suggest that the catalytic behaviour is critically dependent on the fluid dynamics provided by structural characteristics of the supports, such as porosity, density and size of pores. The randomness and tortuosity of foams enhance reactant mixing, as it was evidenced by the higher axial and radial dispersions of the gas flow across the foam structure. This leads to better mass and heat transfers in the reaction system, thus improving the catalytic behaviour.

Abstract: The reactors used for Selective Catalytic Reduction (SCR) of NOx require low pressure drop structured catalyst packing. Structured packings, such as ceramic foams, are gaining increasing interest for application in low pressure drop reactors, membrane reactors and catalytic distillation units. In this work, cobalt ion exchanged mordenite (Co-HMOR)-coated cordierite-based foams produced by the replication method were evaluated for catalytic reduction of NOx with methane. The addition of 0.3 wt.% Pd to 2 wt.% Co-HMOR leads to a material that can convert 50 % NOx to N2 at 450 °C in a reaction mixture containing 2000 ppm CH4, 1000 ppm NOx, 5 % O2 and balance helium, at GHSV=17000 h-1. Although in an early stage of development, an efficient coating procedure was explored and different ways of exchange of Co and Pd cations into mordenite (Si/Al=10) were studied. Additions of 2 wt.% fumed silica enhanced adhesion of the zeolite onto the ceramic foam. Pd-exchanged Co-HMOR showed to be very sensitive to steam. A 50 % decrease in NOx conversion to N2 was observed after Pd/Co-HMOR samples were exposed at 450 °C to a reaction mixture containing 2 vol% H2O. Although further research is needed to ascertain the mechanism of this deactivation behaviour, agglomeration of Pd forming PdO particles is envisaged.

Abstract: The structure and morphological aspects of highly porous (higher than 90%) cordierite (Mg2Al4Si5O18) foams, prepared by a direct foaming method, have been evaluated by Scanning Electron Microscopy analysis. The resulting ceramic foams consisted of a three-dimensional array of struts forming a well-defined open-cell structure. This type of structure seems very attractive for catalyst support purposes. Attempts have been made in order to control the pore structure since it directly affects the physical properties, namely the mechanical strength. In this respect, the use of a dip coating method to improve the strength of the resulting foams was found to be effective in reducing defects (e.g. pores, flaws) in the struts. Based on image analysis, estimated mean cell sizes were about 550 µm whereas strut thicknesses varied in the range of 60-70 µm. The compressive strength of the developed foams increased by one order of magnitude (0.1 to 1 MPa) by increasing the relative density from 0.06 to 0.18.