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Coating of catalyst supports: links between slurry characteristics, coating process and final coating quality

Adegbite, Stephen Ademola (2010)
Ph.D. thesis, University of Birmingham.

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Tightening legislation for vehicles across the world has caused the use of monolith catalysts in automotive emission control to become ubiquitous. Control of the adherence and homogeneity of the platinum group metal (PGM) coating onto the monolith block, to maximise catalytic performance for a minimum PGM loading, is therefore paramount. In this study, an automatic film application is used for coating γ–alumina slurries onto Fecralloy®, an integral component of metallic monolith catalysts, to achieve the desired coating properties. Upon coating of the Fecralloy® coupons, the samples preoxidised for 10 h gave the best performance in terms of coating loading (7.94 mass %) and adherence (< 10 mass % loss) based on ultrasonic vibration test. These conditions produced the optimal surface topography, typified by conspicuous and randomly-oriented α–alumina whiskers which promote coating adherence. The optimal coating loading and adherence were achieved at a pH of 4 and solids concentrations not exceeding 40 wt%. A newly devised technique using the electromechanical testing system showed that finest particle coatings of 40 wt% solids concentration produced the best coating adherence. At solids concentration of 45 wt% the coating adherence was poor and insensitive to the blends of different particle size distributions.

Type of Work:Ph.D. thesis.
Supervisor(s):Barigou, Mostafa and Wagland, Alison and Stitt, Hugh
School/Faculty:Colleges (2008 onwards) > College of Engineering & Physical Sciences
Department:School of Chemical Engineering
Subjects:TP Chemical technology
Institution:University of Birmingham
ID Code:920
This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder.
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