Deposition of Al2O3 layers upon stainless steel substrate utilizing suspension technique towards preparing structured catalysts

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In recent years, interests in the synthesis and utilization of structured catalysts risen. Lower pressure drops, uniform diffusion lengths and higher rates of reaction are considered as the major advantages of these types of materials versus their rivals of various packing of packed beds. The most important step in preparing a reactor containing a structured catalyst understood to be the formation of a well-adhered catalytic layer onto the walls of such a device. However, in almost all prescribed procedures, the catalyst support initially required to be deposited upon the reactor wall and then impregnation of active species occurred. This should be followed by calcination resulting in a desired catalyst layer. The present study focused on the deposition of a thin layer of γ-alumina support with different thicknesses on a stainless steel surface through the suspension method. In this work, boehmite was utilized as the precursor of alumina. Moreover, the phase transition of boehmite into γ-alumina was confirmed through the XRD analysis. Results revealed that, after coating of the surfaces under different suspension compositions, four layers with 35, 53, 75 and 107 μm thicknesses obtained. Finally, the adherence quality through the sonication tests as well as; the specific surface areas via the BET-BJH methods for the coated layers determined. These analyses showed a good quality of adherence of these layers obtained to the substrate as well as; a surface area and average pore size of 69 m2/g and 15.42 nm were revealed for coated material.