CO2 valorisation to methane on highly stable iron impregnated ceria-zirconia based 3D-printed catalyst

• Published in: Journal of CO2 utilization Vol. 72; p. 102501
• Main Authors: Biswas, Saheli, Kundu, Chandan, Ng, Wei Lin, Samudrala, Shanthi Priya, Jarvis, Tom, Giddey, Sarbjit, Bhattacharya, Sankar
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.06.2023
• Subjects: 3D monolith; Catalyst surface area; CO2 utilisation; Fe-ceria-zirconia mixed oxide; In-situ characterisation; Methane selectivity; In-situ characterisation; Methane selectivity; Fe-ceria-zirconia mixed oxide; 3D monolith; Catalyst surface area; CO2 utilisation
• ISSN: 2212-9820; 2212-9839
• DOI: 10.1016/j.jcou.2023.102501

The catalytic activity of 3D-printed metal monoliths loaded with iron impregnated ceria-zirconia mixed-oxide support on CO2 conversion to methane was investigated between 300 and 500 °C under 1 bar and 20 bar pressure. The catalyst was characterised using TPR, XRD, SEM-EDX and in-situ DRIFTS. At 400 °C and atmospheric pressure, the catalyst wash-coated monoliths increased the methane yield by 3.5 times and doubled the CO2 conversion compared to the same catalyst dispersed as a powder. Methane selectivity of 95.2% was obtained at 400 °C and 20 bars pressure. This is the highest methane selectivity recorded in the literature for CO2 methanation using an iron catalyst. The catalyst loaded monoliths were stable over a continuous operation of 100 h at 500 °C and 20 bar. Such increased methane selectivity and yield combined with a long duration stability as well as an economic and easier synthesis process vouches for the great potential of catalyst loaded 3D monoliths for industrial application. •3D-printed Fe-based catalyst tested between 300 and 500 °C under 1 bar and 20 bar.•At 400 °C and 1 bar, methane yield increased by 3.5 times and CO2 conversion doubled.•Methane selectivity of 95.2% obtained at 400 °C and 20 bars pressure.•Catalyst stable over 100 h at 500 °C and 20 bars with average methane selectivity 90.66%.•In-situ DRIFTS studies of fresh and spent catalyst revealed formation of bicarbonate and monodentate carbonate intermediates.