Highly active Co–Al2O3-based catalysts for CO2 methanation with very low platinum promotion prepared by double flame spray pyrolysis

Abstract

Cobalt-based catalysts are often promoted with noble metals to improve the reducibility of the catalyst and provide a high number of metallic Co sites. The high cost of such noble metals requires new synthetic strategies enabling the use of such promoters at as low concentrations as possible. In this article, we present platinum-promoted Co–Al₂O₃ catalysts with very small concentrations of platinum (between 0.03 and 0.43 wt%) synthesized by double flame spray pyrolysis (DFSP) as a very versatile preparation technique. Catalysts with Pt contents as low as 0.03 wt% Pt lead to a significant improvement in the reducibility of Co₃O₄ and to high catalytic activity for the CO₂ methanation reaction compared to non-promoted Co–Al₂O₃. Upon further increasing the Pt content up to 0.43 wt%, only a slight improvement in catalyst reduction and catalytic activity is observed. All prepared catalysts were characterised using XRD, BET, TPR, TEM and EDX followed by catalytic tests for CO₂ methanation. Furthermore, two different preparation schemes were used for DFSP, where platinum was combusted either with Co or with the Al precursor solution in one flame, which results in catalysts with a tight chemical contact between Pt and Co₃O₄ or Pt and Al₂O₃, respectively. Based on TPR and catalytic tests it could be demonstrated that the deposition of platinum on one or the other oxidic phase has no influence on the reducibility and catalytic performance. The conversion and reducibility were similar for both preparation schemes, an observation which can be explained by H₂ spillover during catalyst reduction and catalytic reaction.