Development of Catalytic Converters Using Detonation Spraying

One of the trends in hydrogen power engineering is the development of devices for the preparation of synthesis gas by the catalytic reforming of a hydrocarbon feedstock. Studies show the advantages of catalytic converters based on a modular catalyst support with a honeycomb-type structure produced from a metal foil, both sides of which are coated with highly porous oxide ceramics. The drawback of this design is a poor ability of the coating to withstand high-temperature operating conditions. The coating may detach from the substrate because of the difference in thermal expansion coefficients between the metal foil and the ceramic coating. Besides, a corrosion of metal foil takes place. The result of the present study is the development and application of a two-step coating method, which allows significantly increasing the service life of the catalyst supports. At the first step, a low-porosity ceramic layer is deposited on a metal foil by detonation spraying. At the second step, a high-porosity layer of a ceramic catalyst is deposited from suspension. In this work, the peculiarities of the detonation spraying of the ceramic coating on a metal foil and the design of the obtained catalytic converter have been addressed.