Super-strong adhesion of Fe-ZSM5 catalyst on metal substrate using ceramic powder spray coating for selective catalytic reduction of NOx with NH3

Fe-ZSM5 catalyst coating on stainless steel foil sheets for NOx removal NH3-SCR reaction was prepared using special ceramic powder spray coating (PSC) and conventional wash-coating methods. Super-strong catalyst adhesion on the substrates was obtained using PSC without any binder addition. The conventional slurry coating samples showed much lower adhesion strength than the PSC samples for all catalyst coating layer thicknesses. Honeycomb-shaped monolith catalyst prepared using PSC showed high NOx removal performance comparable to the wash-coated catalyst for both standard and fast NH3-SCR reactions. The PSC catalysts having strong adhesion to metal substrates with good catalytic performance can be a promising candidate for exhaust gas after-treatment exposed to harsh mechanical conditions such as pre-turbocharger applications under very high flow rates of exhaust gas and engine vibration. The excellent catalyst adhesion property can highly enhance long-term mechanical stability of monolith catalysts. [Display omitted] •Fe-ZSM5 catalyst coating layer had super-strong adhesion to metal substrates.•The special ceramic powder spray coating (PSC) method induced super-strong adhesion.•The conventional slurry coating sample showed much lower adhesion strength.•Fe-ZSM5 catalyst prepared using PSC showed high NOx removal performance.•The PSC catalyst is a promising candidate for NH3-SCR in harsh mechanical condition.