Structured Ni(Cl)/CeO₂/η-Al₂O₃/FeCrAl wire mesh catalyst for selective CO methanation

A structured Ni(Cl)/CeO₂/η-Al₂O₃/FeCrAl catalyst was developed and tested for the reaction of selective methanation of CO in the presence of CO₂. The use of a FeCrAlloy wire mesh with a η-Al₂O₃ protective coating as a support of Ni(Cl)/CeO₂ enabled production of a catalyst with the ability of high rates of heat removal, that is similar in performance to the most efficient powder catalysts. In a hydrogen-rich gas mixture of composition (vol%): 1.0 CO, 65 H₂, 10 H₂O, 20 CO₂, He - balance, at WHSV of 29 L g⁻¹ h⁻¹, the Ni(Cl)/CeO₂/η-Al₂O₃/FeCrAl catalyst reduced the CO concentration to a level of <10 ppm in the temperature range of 230–270 °C with a selectivity larger than 70%.