Comparison of the methods for preparing a cordierite monolith-supported Cu-Mn mixed-oxide catalyst

BACKGROUND An efficient, quick and simple preparation method is of great importance for mass production of monolithic catalysts in industry. This paper reports a comparison of three methods used to prepare a monolithic Cu–Mn mixed‐oxide/γ‐alumina/cordierite catalyst. RESULTS The catalysts obtained by different methods have significant differences in catalytic activity and mechanical stability, although their chemical crystalline phases are identical. Similar to a conventional two‐step method, the simple one‐step sol dipping method leads to homogeneous distribution of active phase and hence to greater o‐xylene combustion activity, compared with the one‐step solution impregnation method. Furthermore, the one‐step sol dipping method results in the strongest adhesion and cohesion of catalytic material on to the monolithic substrate, followed by the one‐step solution impregnation method and then the conventional two‐step method. CONCLUSIONS The one‐step sol dipping method is superior to the other two methods and is therefore recommended for use in the future preparation of monolithic catalysts, especially for mass production of monolithic catalysts in industry. © 2013 Society of Chemical Industry