Partial Methane Oxidation into Synthesis Gas over Catalysts Supported on Meshed Metallic Materials

Comparative tests of metal catalysts (Pd, Ni, Co, and Cu on a metal gauze and FeCrAl alloy foil) obtained in two ways-thermochemical and electrochemical metal deposition-have been carried out in order to develop efficient catalysts supported on meshed metallic materials for partial methane oxidation into synthesis gas. The tests have been performed in the 680-1000 degrees C range in a flow reactor (10 mm i.d.) with a catalyst in the form of a rolled metal gauze or FeCrAl foil mounted inside. The metallic supports (gauze and foil) with metals (Pd, Ni) supported on them are promising as catalysts for producing synthesis gas by partial methane oxidation in a narrow range of oxygen : methane molar ratios (O-2 : CH4 = 0.45-0.55). An SEM examination of the catalyst surfaces has demonstrated that the thermochemical deposition of Group VIII metals yields a more branched active metal surface that ensures almost 100% methane conversion at a CO selectivity of >90% even at 900 degrees C.