Mass transfer enhancement and drying mechanism of high adhesion saturated impregnated Co-Al2O3 monolithic catalyst

Abstract The drying process significantly influences the dispersion of metals, physical properties, and performance of monolithic catalysts. In this research, a cordierite-based monolithic catalyst with Co/γ-Al2O3 was prepared using the slurry and impregnation method. The impact of ambient humidity on metal dispersion, mass transfer performance, and catalytic performance was investigated. The findings revealed distinct crystallization-deliquescence curves in the saturated impregnated monolithic catalysts, with alternating crystallization and deliquescence phenomena occurring as the ambient humidity changed. When the coating adhesion was high, the simultaneous occurrence of internal crystallization and surface dissolution resulted in concentrated internal stress, which facilitated the micro-stripping of the coating, leading to the formation of a cobweb-like microstructure. This process affected the distribution of pore sizes and enhanced mass transfer performance. The Co-based catalysts prepared in this study demonstrated a high selectivity for C5+ products (73.93%) when employed in the Fischer-Tropsch synthesis reaction. This research offers an optimization strategy for catalyst preparation, aiming to develop monolithic catalysts with low melting points, high crystallinity, and supersaturated supported transition metals.