Synthesis of ferrierite coatings on the FeCrAl substrate

Zeolite coatings on metal substrates are highly desirable materials that can be used as efficient catalysts. In this paper we report on preparation of ferrierite type zeolite coatings on a pre-oxidized metal substrate. Ferrierite was chosen due to its unique catalytic properties, including potential application in nitrogen oxides removal. FeCrAl ferritic steel was used as a substrate. The FeCrAl foil was oxidized in air at 800 °C. The in situ synthesis of ferrierite on the FeCrAl substrate and in bulk were studied using XRD, laser diffraction (LD) and scanning electron microscopy (SEM). Various conditions were applied for coatings preparation, including static and dynamic syntheses, variable nucleation time and type of a gel used. The kinetics of ferrierite crystallization is also reported.