A unique
catalyst structure, microfibrous entrapped catalyst (MFEC),
was prepared by entrapping support particles (γ-Al2O3, 150–250 μm diam) into metal (Ni-200)
microfibers and forming thin flexible sheets. Pleated structures of
MFECs containing Pd/γ-Al2O3, Pd–Mn/γ-Al2O3, and Pd–Ce/γ-Al2O3 were investigated systematically for volatile organic compound
(VOC) removal at various face velocities (ca. 3–30 m/s) and
at low temperatures (<473 K). The optimized structure of MFEC (e.g.,
W-structure with 8 μm Ni fiber) resulted intralayer residence
times from 750 to 65 μs with pressure drops from 0.35 to 10.22
kPa. The study exhibited that low intralayer residence times had a
significant effect on the catalytic reaction which followed the Mars–Van
Krevelen mechanism in this velocity controlled region. The overall
reaction rate for VOC removal was limited by the surface reaction.
Furthermore, mixed metal oxide based MFECs showed better performance
in VOC removal due to the high oxygen storage capacity of reducible
oxides. The performance of pleated MFEC was calculated in terms of
heterogeneous contacting efficiency (ηHCE), which
relies on the logarithmic removal of reactant concentrations per unit
of the pressure drop.