Ru/Ce/Ni Metal Foams as Structured Catalysts for the Methanation of CO2

The development of highly conductive structured catalysts with enhanced mass- and heat-transfer features is required for the intensification of the strongly exothermic catalytic hydrogenation of CO2 in which large temperature gradients should be avoided to prevent catalyst deactivation and to control selectivity. Therefore, in this work we set out to investigate the preparation of novel structured catalysts obtained from a commercial open cell Ni foam with high pore density (75 ppi) onto which a CeO2 layer was deposited via electroprecipitation, and, eventually, Ru was added by impregnation. Composite Ru/Ce/Ni foam catalysts, as well as simpler binary Ru/Ni and Ce/Ni catalysts were characterized by SEM-EDX, XRD, cyclic voltammetry, N-2 physisorption, H-2-temperature programmed reduction (TPR), and their CO2 methanation activity was assessed at atmospheric pressure in a fixed bed flow reactor via temperature programmed tests in the range from 200 to 450 degrees C. Thin porous CeO2 layers, uniformly deposited on the struts of the Ni foams, produced active catalytic sites for the hydrogenation of CO2 at the interface between the metal and the oxide. The methanation activity was further boosted by the dispersion of Ru within the pores of the CeO2 layer, whereas the direct deposition of Ru on Ni, by either impregnation or pulsed electrodeposition methods, was much less effective.