Effective Ce-based catalysts deposition on ceramic open cell foams

In this work, ceramic powder dispersion was achieved by using a glycerol/water solution as dispersion medium and polyvinyl alcohol as binder and rheology modifier. Five different powders were dispersed and they were deposited onto open cell ceramic foams: the bare carrier (i.e. cerium oxide) and four catalytically active powders (i.e. nickel, cobalt, iron and copper oxides supported on ceria). Catalysts powders have been extensively characterized and were demonstrated to be suitable samples candidates of model powders for the deposition onto open-cell foams. Rheological properties were found to be related to the dispersed powder, thus directly affecting washcoat load. Multiple depositions were performed by means of dip-coating on 20, 30 and 40 PPI Y-stabilized ZrO2 open cell foams. Depending on formulation and foam pore density, coating loads in the 6–30 % wt. range were obtained. Washcoat layers were found to be quite homogeneous and well adherent therefore suitable for catalytic applications, such as for instance the methane steam reforming synthesis for Ni-based catalysts.