Activity and characterization of Rh/Al2O3 and Rh-Na/Al2O3 catalysts for the SCR of NO with CO in the presence of SO2 and HCl

SO₂ and HCl are major pollutants emitted from waste incineration processes. Both pollutants are difficult to remove completely and can enter the catalytic reactor. In this work, the effects of SO₂ and HCl on the performance of Rh/Al₂O₃ and Rh-Na/Al₂O₃ catalysts for NO removal were investigated in simulated waste incineration conditions. The characterizations of the catalysts were analyzed by BET, SEM/EDS, XRD, and ESCA. Experimental results indicated the 1%Rh/Al₂O₃ catalyst was significantly deactivated for NO and CO conversions when SO₂ and HCl coexisted in the flue gas. The addition of between 2 and 10 wt.% Na promoted the activity of the 1%Rh/Al₂O₃ catalyst for NO removal, but decreased the CO oxidation and BET surface area. The catalytic activity for NO removal was inhibited by HCl as a result of the formation of RhCl₃. Adding Na to the Rh/Al₂O₃ catalyst decreased the inhibition of SO₂ because of the formation of Na₂SO₄, which was observed in the XRD and ESCA analyses. SEM mapping/EDS showed that more S was residual on the surface of the Rh-Na/Al₂O₃ catalyst than Cl.     

Catalytic removal of NO in waste incineration processes over Rh/Al2O3 and Rh–Na/Al2O3: Effects of particulates,heavy metals,SO2 and HCl

Two novel catalysts Rh/Al₂O₃ and Rh–Na/Al₂O₃ were prepared for NO removal and tested their practical performances in a laboratory-scale waste incineration system. The effects of particulates, heavy metals, and acid gases on the catalysts were evaluated and investigated through several characterization techniques, such as SEM, EA, XRPD, ESCA, and FTIR. The results indicated that the NO conversions were increased with the accumulation of particulates on the surface of catalysts, which was attributed to the increase in carbon content. However, the increase in heavy metals Cd and Pb contents on the surface of catalysts decreased the activity of catalyst for NO removal but did not change the chemical state of Rh and Na. The Rh/Al₂O₃ catalysts were poisoned when the acid gases SO₂ and HCl were present in the flue gas, because Rh and Al reacted with S and Cl to form inactive products. Adding Na to Rh/Al₂O₃ catalysts produced a promoting effect for SO₂ removal due to the formation of Na₂SO₄. The influence levels of different pollutants on the performances of Rh/Al₂O₃ and Rh–Na/Al₂O₃ catalysts for NO removal followed the sequence of HCl > heavy metals > SO₂ > particles.     

Efficient production of hydrogen and multi-walled carbon nanotubes from ethanol over Fe/Al2O3 catalysts

Fe/Al₂O₃ catalysts with different Fe loadings (10-90 mol%) were prepared by hydrothermal method. Ethanol decomposition was studied over these Fe/Al₂O₃ catalysts at temperatures between 500 and 800 °C to produce hydrogen and multi-walled carbon nanotubes (MWCNTs) at the same time. The results showed that the catalytic activity and stability of Fe/Al₂O₃ depended strongly on the Fe loading and reaction temperature. The Fe(30 mol%)/Al₂O₃ and Fe(40 mol%)/Al₂O₃ were both the effective catalyst for ethanol decomposition into hydrogen and MWCNTs at 600 °C. Several reaction pathways were proposed to explain ethanol decomposition to produce hydrogen and carbon (including nanotube) at the same time.     

Evaluation of hot corrosion behavior of CSZ,CSZ/micro Al2O3 and CSZ/nano Al2O3 plasma sprayed thermal barrier coatings

Hot corrosion is one of the main destructive factors in thermal barrier coatings (TBCs) which come as a result of molten salt effect on the coating–gas interface. Hot corrosion behavior of three types of plasma sprayed TBCs was evaluated: usual CSZ, layer composite of CSZ/Micro Al₂O₃ and layer composite of CSZ/Nano Al₂O₃ in which Al₂O₃ was as a topcoat on CSZ layer. Hot corrosion studies of plasma sprayed thermal barrier coatings (TBCs) were conducted in 45 wt% Na₂SO₄+55 wt% V₂O₅ molten salt at 1050 °C for 40 h. The graded microstructure of the coatings was examined using scanning electron microscope (SEM) and X-ray diffractometer (XRD) before and after hot corrosion test. The results showed that no damage and hot corrosion products was found on the surface of CSZ/Nano Al₂O₃ coating and monoclinic ZrO₂ fraction was lower in CSZ/Micro Al₂O₃ coating in comparison with usual CSZ. reaction of molten salts with stabilizers of zirconia (Y₂O₃ and CeO₂) that accompanied by formation of monoclinic zirconia, irregular shape crystals of YVO₄, CeVO₄ and semi-cubic crystals of CeO₂ as hot corrosion products, caused the degradation of CSZ coating in usual CSZ and CSZ/Micro Al₂O₃ coating.     

Steam reforming of LPG over Ni and Rh supported on Gd-CeO2 and Al2O3: Effect of support and feed composition

The steam reforming of liquefied petroleum gas (LPG) over Ni- and Rh-based catalysts supported on Gd-CeO₂ (CGO) and Al₂O₃ was studied at 750-900 °C. The order of activity was found to be Rh/CGO > Ni/CGO ∼ Rh/Al₂O₃ > Ni/Al₂O₃; we indicated that the comparable activity of Ni/CGO to precious metal Rh/Al₂O₃ is due to the occurring of gas-solid reactions between hydrocarbons and lattice oxygen () on CGO surface along with the reaction taking place on the active site of Ni, which helps preventing the carbon deposition and promoting the steam reforming of LPG.The effects of O₂ (as oxidative steam reforming) and H₂ adding were further studied over Ni/CGO and Ni/Al₂O₃. It was found that the additional of these compounds significantly reduced the amount of carbon deposition and promoted the conversion of hydrocarbons (i.e., LPG as well as CH₄, C₂H₄ and C₂H₆ occurred from the thermal decomposition of LPG) to CO and H₂. Nevertheless, the addition of too high O₂ oppositely decreased H₂ yield due to the oxidizing of Ni particle and the possible combusting of H₂ generated from the reaction, while the addition of too high H₂ also negatively affect the catalyst activity due to the occurring of catalyst active site competition and the inhibition of gas-solid reactions between the gaseous hydrocarbon compounds and on the surface of CGO (for the case of Ni/CGO).     

Influence of glass phase on Al2O3 fiber-reinforced Al2O3 composites processed by slip casting

The present work describes the processing of alumina fiber reinforced alumina ceramic preforms consisting of chopped Al₂O₃ fibers (33 wt%) and Al₂O₃ (67 wt%) fine powders by slip casting. The preforms were pre-sintered in air at 1100 °C for 1 h. A lanthanum based glass was infiltrated into these preforms at 1250 °C for 90 min. Linear shrinkage (%) was studied before and after glass infiltration. Pre-sintered and infiltrated specimens were characterized by scanning electron microscopy, energy dispersive X-ray, X-ray diffraction, porosimetry and flexural strength. The alumina preforms showed a narrow pore size distribution with an average pore size of ∼50 nm. It was observed that introducing Al₂O₃ fibers into Al₂O₃ particulate matrix produced warp free preforms with minor shrinkage during pre-sintering and glass infiltration. It was observed that the infiltration process fills up the pores and considerably improves the strength and reliability of alumina preform.     

Processing and physical properties of Al2O3/aluminum alloy composites

Porous aluminum oxide (Al₂O₃) preforms were formed by sintering in air at 1200 °C for 2 h. A356, 6061, and 1050 aluminum alloys were infiltrated into the preforms by squeeze casting in order to fabricate Al₂O₃/A356, Al₂O₃/6061, and Al₂O₃/1050 composites, respectively, with different volumes of aluminum alloy content. The content of aluminum alloy in the composites was 10–40% by volume. The resistivity of Al₂O₃/A356, Al₂O₃/6061, and Al₂O₃/1050 composites decreased dramatically from 6.41 × 10¹² to 9.77 × 10⁻⁴, 7.28 × 10⁻⁴, and 6.24 × 10⁻⁴ Ω m, respectively, the four-points bending strength increased from 397 to 443, 435.1, 407.2 MPa, respectively, and the deviations were smaller than 2%. From SEM microstructural analysis and TEM bright field images, the pore volume fraction and the relative density of the composites were the most important factors that affected the physical and mechanical properties. The ceramic phase and alloy phase in Al₂O₃/aluminum alloy composites were found to be homogenized and uniformly distributed using electrical and mechanical properties analysis, microstructure analysis, and image analysis.     

Phase diagram of the Al2O3-HfO2-Y2O3 system

The phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system was first constructed in the temperature range 1200-2800 °C. The phase transformations in the system are completed in eutectic reactions. No ternary compounds or regions of appreciable solid solution were found in the components or binaries in this system. Four new ternary and three new quasibinary eutectics were found. The minimum melting temperature is 1755 °C and it corresponds to the ternary eutectic Al₂O₃ + HfO₂ + Y₃Al₅O₁₂. The solidus surface projection, the schematic of the alloy crystallization path and the vertical sections present the complete phase diagram of the Al₂O₃-HfO₂-Y₂O₃ system.     

Composite Ni/Al2O3 coatings and their corrosion resistance

Composite coatings Ni/Al₂O₃ were electrochemically deposited from a Watts bath. Al₂O₃ powder with particle diameter below 1 μm was codeposited with the metal. The obtained Ni/Al₂O₃ coatings contained 5-6% by weight of corundum. The structure of the coatings was examined by scanning electron microscopy (SEM). It has been found that the codeposition of Al₂O₃ particles with nickel disturbs the nickel coating's regular surface structure, increasing its microcrystallinity and surface roughness. DC and AC electrochemical tests were carried out on such coatings in a 0.5 M solution of Na₂SO₄ in order to evaluate their corrosion resistance. The potentiodynamic tests showed that the corrosion resistance of composite coating Ni/Al₂O₃ is better than that of the standard nickel coating. After 14 days of exposure the nickel coating corrodes three times faster than the Ni/Al₂O₃ coating. The electrochemical behaviour of the coatings in the corrosive solution was investigated by electrochemical impedance spectroscopy (EIS). An equivalent circuit diagram consisting of two RC electric circuits: one for electrode, nickel corrosion processes and the other for processes causing coating surface blockage, were adopted for the analysis of the impedance spectra. The changes in the charge transfer resistance determined from the impedance measurements are comparable with the changes in corrosion resistance determined from potentiodynamic measurements.     

Preparation and electrical properties of graphene nanosheet/Al2O3 composites

Fully dense graphene nanosheet(GNS)/Al₂O₃ composites with homogeneously distributed GNSs of thicknesses ranging from 2.5 to 20 nm have been fabricated from ball milled expanded graphite and Al₂O₃ by spark plasma sintering. The percolation threshold of electrical conductivity of the as-prepared GNS/Al₂O₃ composites is around 3 vol.%, and this new composite outperforms most of carbon nanotube/Al₂O₃ composites in electrical conductivity. The temperature dependence of electrical conductivity indicated that the as-prepared composites behaved as a semimetal in a temperature range from 2 to 300 K.     

Sintering of Al2O3-SiC composite from sol-gel method with MgO, TiO2 and Y2O3 addition

Al₂O₃-SiC composite ceramics were prepared by pressureless sintering with and without the addition of MgO, TiO₂ and Y₂O₃ as sintering aids. The effects of these compositional variables on final density and hardness were investigated. In the present article at first α-Al₂O₃ and β-SiC nano powders have been synthesized by sol-gel method separately by using AlCl₃, TEOS and saccharose as precursors. Pressureless sintering was carried out in nitrogen atmosphere at 1600 °C and 1630 °C. The addition of 5 vol.% SiC to Al₂O₃ hindered densification. In contrast, the addition of nano MgO and nano TiO₂ to Al₂O₃-5 vol.% SiC composites improved densification but Y₂O₃ did not have positive effect on sintering. Maximum density (97%) was achieved at 1630 °C. Vickers hardness was 17.7 GPa after sintering at 1630 °C. SEM revealed that the SiC particles were well distributed throughout the composite microstructures. The precursors and the resultant powders were characterized by XRD, STA and SEM.     

Effect of CeO2 addition on densification and microstructure of Al2O3-YSZ composites

Alumina (Al₂O₃) and alumina-yttria stabilized zirconia (YSZ) composites containing 3 and 5 mass% ceria (CeO₂) were prepared by spark plasma sintering (SPS) at temperatures of 1350-1400 °C for 300 s under a pressure of 40 MPa. Densification, microstructure and mechanical properties of the Al₂O₃ based composites were investigated. Fully dense composites with a relative density of approximately 99% were obtained. The grain growth of alumina was inhibited significantly by the addition of 10 vol% zirconia, and formation of elongated CeAl₁₁O₁₈ grains was observed in the ceria containing composites sintered at 1400 °C. Al₂O₃-YSZ composites without CeO₂ had higher hardness than monolithic Al₂O₃ sintered body and the hardness of Al₂O₃-YSZ composites decreased from 20.3 GPa to 18.5 GPa when the content of ZrO₂ increased from 10 to 30 vol%. The fracture toughness of Al₂O₃ increased from 2.8 MPa m^1/2 to 5.6 MPa m^1/2 with the addition of 10 vol% YSZ, and further addition resulted in higher fracture toughness values. The highest value of fracture toughness, 6.2 MPa m^1/2, was achieved with the addition of 30 vol% YSZ.     

Pulsed electric current sintering of transparent Cr-doped Al2O3

Pulsed electric current sintering (PECS) was applied to obtain transparent ruby polycrystals. Al₂O₃-Cr₂O₃ powder mixture was prepared by drying an aqueous slurry consisting of Al₂O₃ and Cr(NO₃)₃ followed by PECS consolidation in vacuum at a sintering temperatures ranging from 1100 to 1300 °C with various heating rates between 2 and 100 °C/min and under an applied pressures from 40 to 100 MPa. Slow heating rate and high-pressure lead to highly densified and transparent Cr-doped Al₂O₃ polycrystals at sintering temperature of 1200 °C.     

Mixtures of carbon and Ni/Al2O3 as catalysts for the microwave-assisted CO2 reforming of CH4

In this work, the microwave-assisted CO₂ reforming of CH₄ over mixtures of carbonaceous materials and an in-lab prepared Ni/Al₂O₃ was studied. Ni/Al₂O₃ is not heated by microwave radiation, and for this reason, microwave receptors, such as carbonaceous materials, must be mixed with this catalyst. In order to evaluate the role of the carbonaceous component of the blend, two different carbonaceous materials were used: an activated carbon, FY5, and a metallurgical coke, CQ. The carbonaceous component acted not only as microwave receptor but also as catalyst and, consequently, it influenced the catalytic activity of the mixture. FY5 + Ni/Al₂O₃ was found to be a better catalyst than CQ + Ni/Al₂O₃, since FY5 on its own showed a better catalytic activity than CQ. Ni/FY5, which consists of Ni impregnated directly onto the microwave receptor, was also evaluated as a catalyst. It was found that the catalytic activity of the mixture FY5 + Ni/Al₂O₃ was better than that of Ni/FY5. Finally, the influence of the heating device on the catalytic activity of FY5 + Ni/Al₂O₃ was studied. Conversions over FY5 + Ni/Al₂O₃ and microwave heating were found to be similar to conversions over Ni/Al₂O₃ and conventional heating.     

Effects of CaSiO3 addition on sintering behavior and microwave dielectric properties of Al2O3 ceramics

The effects of CaSiO₃ addition on the sintering behavior and microwave dielectric properties of Al₂O₃ ceramics have been investigated. The addition of CaSiO₃ into Al₂O₃ ceramics resulted in the emergence of Ca₂Al₂SiO₇ and CaAl₂Si₂O₈, which acting as liquid sintering aids can effectively lower the sintering temperature of Al₂O₃ ceramic. The Q × f value of Al₂O₃-CaSiO₃ ceramics decreased with the CaSiO₃ addition increasing because of the lower Q × f value of Ca₂Al₂SiO₇ and CaAl₂Si₂O₈. Compared with the pure CaSiO₃ ceramic, the Al₂O₃-CaSiO₃ ceramic with 20 wt% CaSiO₃ addition possessed good dielectric properties of ?_r = 9.36 and Q × f = 13,678 GHz at the similar sintering temperature.     

Improving the Activity of Rh/Al2O3 Catalyst for NO Reduction by Na Addition in the Presences of H2O and O2

The effect of Na addition on the performance of Rh/Al₂O₃ catalyst for NO reduction with CO in the presence of H₂O and O₂ was investigated. The reacted catalysts were analyzed by the FTIR technique to identify the products for further investigation on the possible catalytic reaction mechanisms and the reasons behind the H₂O poisoning. Experimental results show that the removal efficiency of NO by Rh/Al₂O₃ catalyst was 63% at 250 °C but that decreased as the H₂O content increased. Adding Na to modify the Rh/Al₂O₃ catalyst significantly enhanced the conversion of NO to 99% at 250–300 °C even as the H₂O content was 1.6 vol%. The FTIR analyses results reveal that the abundant H₂O in the flue gas can compete with NO to adsorb on the surfaces of Rh/Al₂O₃ and Rh-Na/Al₂O₃ catalysts and further enhance the formation of NO₃ that reacts with H. The effects of H₂O on Rh/Al₂O₃ and Rh-Na/Al₂O₃ catalysts can be eliminated by increasing the reaction temperature to higher than 300 °C. Rh-Na/Al₂O₃ is a feasible catalyst for NO reduction at such condition with relative high H₂O and O₂ contents.     

CVD synthesis of Al2O3 nanotubular structures using a powder source

Alumina (Al₂O₃) 1D nanotubular structures were synthesized by chemical vapor deposition (CVD) using aluminum (Al) and Al₂O₃ powder sources at a temperature of 1300 °C and a pressure of 100 Pa. At present, no research has been published regarding the synthesis of α-phase Al₂O₃ nanotubes using only a powder source. In this work, we attempted to grow α-phase Al₂O₃ nanotubes without catalysts. As-deposited nanotubular structures had an irregular and ragged surface morphology that was related to the boundary layer thickness. Moreover, complementary nanotubular structures can be obtained via an annealing process. A model to describe the irregular nanotubular structure formation was suggested, and the effect of the boundary layer thickness was demonstrated in our experimental conditions.     

Corrosion mechanisms of Al2O3/MgAl2O4 by V2O5, NiO, Fe2O3 and vanadium slag

The effects of V₂O₅, NiO, Fe₂O₃ and vanadium slag on the corrosion of Al₂O₃ and MgAl₂O₄ have been investigated. The specimens of Al₂O₃ and MgAl₂O₄ with the respective oxides above mentioned were heated at 10 °C/min from room temperature up to three different temperatures: 1400, 1450 and 1500 °C. The corrosion mechanisms of each system were followed by XRD and SEM analyses. The results obtained showed that Al₂O₃ was less affected by the studied oxides than MgAl₂O₄. Alumina was only attacked by NiO forming NiAl₂O₄ spinel, while the MgAl₂O₄ spinel was attacked by V₂O₅ forming MgV₂O₆. It was also observed that Fe₂O₃ and Mg, Ni, V and Fe present in the vanadium slag diffused into Al₂O₃. On the other hand, the Fe₂O₃ and Ca, S, Si, Na, Mg, V and Fe diffused into the MgAl₂O₄ structure. Finally, the results obtained were compared with those predicted by the FactSage software.     

Effects of Al2O3 addition on the sintering behavior and microwave dielectric properties of CaSiO3 ceramics

The effects of Al₂O₃ addition on the densification, structure and microwave dielectric properties of CaSiO₃ ceramics have been investigated. The Al₂O₃ addition results in the presence of two distinct phases, e.g. Ca₂Al₂SiO₇ and CaAl₂Si₂O₈, which can restrict the growth of CaSiO₃ grains by surrounding their boundaries and also improve the bulk density of CaSiO₃-Al₂O₃ ceramics. However, excessive addition (≥2 wt%) of Al₂O₃ undermines the microwave dielectric properties of the title ceramics since the derived phases of Ca₂Al₂SiO₇ and CaAl₂Si₂O₈ have poor quality factor. The optimum amount of Al₂O₃ addition is found to be 1 wt%, and the derived CaSiO₃-Al₂O₃ ceramic sintered at 1250 °C presents improved microwave dielectric properties of ?_r = 6.66 and Q × f = 24,626 GHz, which is much better than those of pure CaSiO₃ ceramic sintered at 1340 °C (Q × f = 13,109 GHz).     

Synthesis of SrAl2O4 and Sr3Al2O6 at high temperature, starting from mechanically activated SrCO3 and Al2O3 in blends of 3:1 molar ratio

The synthesis of strontium aluminates of the SrAl₂O₄ and Sr₃Al₂O₆ type using SrCO₃-Al₂O₃ blends was investigated. Blends 3:1 molar ratio of Al₂O₃ and mechanically activated SrCO₃ were prepared and conformed into pellets by uniaxial compression at 100 MPa. In an experimental stage, thermogravimetric analysis was used to investigate the isothermal decomposition of mechanically activated SrCO₃ powders in the blend, in the range of temperatures from 900 to 1100 °C. Then, samples were sintered at 1450 °C for several periods of time (4-36 h), and the products obtained were analyzed by X-ray diffraction and scanning electron microscopy. The results obtained showed that the formation of Sr₃Al₂O₆ starts after 4 h of heat treatment, and it is completed at 36 h. Moreover, other phase such as SrAl₂O₄ formed in small amounts in the samples sintered for 12 h. Kinetic measurements showed that the conversion of SrCO₃ into Sr₃Al₂O₆ follow two different reaction mechanisms, with different controlling steps. The first mechanism relates to the order of reaction model for the Sr₃Al₂O₆ phase formation, whereas the second mechanism relates to the nucleation and growth of these phase particles. The activation energy measured for both processes was 88.59 kJ and 54.06 kJ, respectively.