Preparation of a microfibrous Fe/LTA zeolite membrane catalyst for acetone oxidation: effect of the preparation method

Chemical vapor deposition (CVD) and impregnation (IM) methods were applied in the preparation of novel Fe/LTA (Linde Type A) zeolite membrane/paper-like sintered stainless steel fiber (Fe/LTA/PSSF) catalysts for acetone oxidation. The catalysts were characterized using various techniques, such as actual iron loading (AAS), surface morphology (SEM), phase composition and crystallite size (XRD), specific surface area (BET), valence state (XPS) and reducibility (H-2-TPR), to investigate the effects of the calcination process, iron loading, preparation methods and supports on their catalytic activity. The calcined catalysts were more active than the non-calcined catalysts in the catalytic oxidation of acetone due to the different oxidation states of the deposited metal species. The catalysts prepared by CVD with an Fe loading of 2.29% exhibited similar activity to the IM-prepared catalysts with Fe loadings of 4.42% and 9.69%, which may be attributed to the superior dispersion of the active Fe2O3 phases, the smaller size of metal oxide and the increased ability for oxygen storage. Among the IM-prepared catalysts, Fe/LTA/PSSF-IM-2 with an Fe loading of 4.42% exhibited the lowest T-90 of 230 degrees C. Additionally, the catalysts coated on LTA/PSSF showed higher activity and contact efficiency (T-90 of 249 degrees C) compared to those on granular zeolite (T-90 of 318 degrees C).