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overall foam metal catalysts

Foam metal catalysts are a type of catalytic material with a porous foam-like structure. They are typically made from metal or metal alloys, and their unique structure provides a high surface area for catalytic reactions. Foam metal catalysts have been used in various industrial applications, including automotive catalytic converters, fuel cells, and various chemical processes.

Nickel Foam (6)

In comparison to conventional catalysts, foam metal catalysts offer several advantages:

  1. High surface area: Foam metal catalysts have a highly porous structure, providing a large contact area for reactants to interact with the catalyst. This increased contact area gives the catalyst higher catalytic activity.
  2. Bettermass transfer efficiency: The porous structure of foam metal catalysts also allows for better mass transfer of reactants and products, leading to enhanced reaction rates.
  3. Enhanced stability of physical and chemical properties: Foam metal catalysts are typically more stable than other catalysts, as they are less prone to deactivation due to factors such as sintering, fouling, and poisoning.
  4. Higher selectivity: Foam metal catalysts can exhibit high selectivity for specific reactions, reducing the formation of unwanted by-products and increasing the yield of desired products.
  5. Versatility: Foam metal catalysts are versatile and can be utilized in various industries, including chemical, petrochemical, and pharmaceutical industries, as well as environmental remediation and energy production.

Overall catalysts are the primary choice for catalytic combustion treatment of VOCs in industry. As one of the commonly used carriers, foam metal not only offers benefits such as low pressure drop and good resistance to mechanical impact, but also has a porous structure on the surface. However, there is still room for improvement in terms of its specific surface area. Therefore, it is very important to have a coating that can enhance the specific surface area of the catalyst and improve the dispersibility of the active substance on the catalyst surface. At the same time, high catalytic efficiency also relies on the action of suitable active substances. Therefore, the selection of suitable active substances is vital for achieving high catalytic efficiency. In the selection of active substances, transition metals, such as Co and Ce, are advantageous due to their low cost, abundant reserves, wide availability, and strong catalytic activity. These elements exhibit higher catalytic efficiency for VOCs among the transition metals.

Roll Type Ultra-Thin Foam Copper (7)

One example of a foam metal catalyst is foam nickel, which has been used for the hydrogenation of vegetable oils and the catalytic reduction of nitroaromatic compounds. Another example is foam copper, which has been used for the electrochemical reduction of carbon dioxide to produce fuel. Foam metal catalysts can be tailored to suit specific reactions by modifying their composition, structure, and surface properties. For instance, by incorporating other metals or metal oxides to foam metals can enhance the activity, selectivity, and stability of the catalysts.

Through extensive research and exploration, scientists have discovered that foam metals, as catalyst substrates, exhibit good performance in catalytic oxidation removal of volatile organic compounds (VOCs) when loaded with active substances.

A foam nickel-based catalyst with excellent catalytic performance for benzene was prepared by an electro-deposition method. The active phase of NiCo2O4 was firmly anchored on the foam nickel support through electro-deposition, exhibiting a strong orientation and a nanowire-like structure at the microscopic level. This catalyst has a large specific surface area, abundant oxygen vacancies, and a high Co3+/Co2+ ratio. Among these characteristics, the CoNi-NF-2:1 sample showed excellent activity, achieving a benzene conversion rate of only 198℃ when subjected to a gas hourly space velocity (GHSV) of 6000 mL·g-1·h-1.

Copper Foam, What Is The Application Prospect Of This New Material-1

A foam substrate made of copper was utilized to create catalysts consisting of single metal oxides (Cu, Ce, and Co) as well as composite metal oxides using the impregnation method. Through the catalytic activity test of toluene, it was found that the catalytic activity of the composite metal oxide catalyst was superior to that of the single metal oxide catalyst. This indicates that the interaction between metals promotes the catalytic reaction. Among them, the Co1Ce2@Cu-F catalyst showed the best performance in terms of space velocity and stability. The results indicated that that with the Co1Ce2@Cu-F catalyst, a toluene conversion rate of 90% was achieved at a mass velocity of 15000 mL·g-1·h-1 and a temperature of 237°C. Even after three cycles, the catalytic activity of the catalyst towards toluene did not show a significant decrease, and it still achieved a toluene conversion rate of over 90% at 250°C, demonstrating good cyclic stability. Furthermore, even when the space velocity was increased to 25000 mL·g-1·h-1, the catalyst still exhibited high catalytic activity.

In summary, foam metal catalysts offer many advantages compared to traditional catalysts. Their unique structure makes them a promising technology for catalytic reactions in various fields, providing a promising avenue for improving the efficiency and sustainability of many chemical processes. Ongoing research in this area continues to explore new possibilities and applications for foam metal catalysts.


Picture of Lu


Our materials research team from Tsinghua University postdoctoral researcher lin and Harbin Institute of Technology researcher Mu, Nanjing University of Technology researcher Wei, they share their expertise in foam metal materials article.

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WE were established in 2003, located in the Gaoxin Zone of Guangdong-Guangxi Cooperation Special Experimental Zone, covering an area of 70 mu, with a plant of about 30,000 square meters, with more than 170 employees, is an advanced new material technology enterprise integrating research and development, production and sales.

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