Abstract
Metal foams are interesting supports for the preparation of electrocatalysts and catalysts for gas-phase processes, like partial and total low-temperature oxidation of hydrocarbons and other chemicals, owing to their large surface area, electrical conductivity, efficient mass and heat transfer, mechanical strength and resistance to oxidation. High catalytic activity in specific processes can be imparted to metal foams by the deposition of appropriately chosen noble metal nanoparticles. Deposition may be achieved electrochemically or through spontaneous deposition processes based on galvanic displacement reactions in which a noble metal displaces a less noble one. In the materials prepared by these methods, noble metal nanoparticles are in direct electrical contact with metal foams, so cyclic voltammetry may be effectively used to determine their surface area, a parameter of primary importance in heterogeneous catalysis. These features are illustrated by reviewing the preparation, characterization and catalytic testing of various noble-metal-modified Ni and Fe–Cr–Al alloy metal foams, highlighting advantages and limitations of the proposed methods, as compared with state of the art approaches.
Similar content being viewed by others
References
Alkire RC, Kibler LA, Kolb DM, Lipkowski J (eds) (2013) Advances in electrochemical science and engineering. In: Electrocatalysis: theoretical foundations and model experiments. vol 14. Wiley-VCH, Weinheim
Lavacchi A, Miller H, Vizza F (2013) Nanotechnology in electrocatalysis for energy. Springer, New York
Cybulski A, Moulijn J (eds) (2006) Structured catalysts and reactors, 2nd edn. Taylor & Francis, Boca Raton
Ertl G, Knözinger H, Weitkamp J (eds) (2007) Handbook of heterogeneous catalysis. VCH, Weinheim
Langlois S, Coeuret F (1989) Flow-through and flow-by porous electrodes of nickel foam I. Material characterization. J Appl Electrochem 19:43–50
Langlois S, Coeuret F (1989) Flow-through and flow-by porous electrodes of nickel foam. II. Diffusion-convective mass transfer between the electrolyte and the foam. J Appl Electrochem 19:51–60
Yamauchi Y, Komatsu M, Takai A, Sebata R, Sawada M, Momma T, Fuziwara M, Osaka T, Kuroda K (2007) Direct deposition of nanostructured Pt particles onto a Ni foam from lyotropic liquid crystalline phase by displacement plating. Electrochim Acta 53:604–609
Bidault F, Brett DJL, Middleton PH, Abson N, Brandon NP (2009) A new application for nickel foam in alkaline fuel cells. Int J Hydrogen Energy 34:6799–6808
He H, Liu H, Liu F, Zhou K (2006) Structures and electrochemical properties of amorphous nickel sulphur coatings electrodeposited on the nickel foam substrate as hydrogen evolution reaction cathodes. Surf Coat Technol 201:958–964
Yang B, Yu G, Shuai D (2007) Electrocatalytic hydrodechlorination of 4-chlorobiphenyl in aqueous solution using palladized nickel foam cathode. Chemosphere 67:1361–1367
Kvernes I, Oliveira M, Kofstad P (1977) High temperature oxidation of Fe-13Cr-xAl alloys in air/H2O vapour mixtures. Corros Sci 17:237–252
Cerri I, Pavese M, Saracco G, Specchia V (2003) Premixed metal fibre burners based on a Pd catalyst. Catal Today 83:19–31
Giani L, Cristiani C, Groppi G, Tronconi E (2006) Washcoating method for Pd/γ-Al2O3 deposition on metallic foams. Appl Catal B 62:121–131
Basile F, Benito P, Del Gallo P, Fornasari G, Gary D, Rosetti V, Scavetta E, Tonelli D, Vaccari A (2008) Highly conductive Ni steam reforming catalysts prepared by electrodeposition. Chem Commun 25:2917–2919
Basile F, Benito P, Fornasari G, Rosetti V, Scavetta E, Tonelli D, Vaccari A (2009) Electrochemical synthesis of novel structured catalysts for H2 production. Appl Catal B 91:563–572
Benito P, Monti M, Bersani I, Basile F, Fornasari G, Scavetta E, Tonelli D, Vaccari A (2012) Coating of Fecralloy foam with Rh catalysts: optimization of electrosynthesis parameters and catalyst composition. Catal Today 197:162–169
Verlato E, Barison S, Cimino S, Dergal F, Mancino G, Lisi L, Musiani M, Vázquez-Gómez L (2014) Catalytic partial oxidation of methane over nanosized Rh catalyst supported on Fecralloy foams. Int J Hydrogen Energy 39:11473–11485
Vázquez-Gómez L, Cattarin S, Comisso N, Guerriero P, Musiani M, Verlato E (2012) Spontaneous deposition of Pd onto Fe-Cr-Al alloys. Electrochim Acta 68:114–122
Cimino S, Gerbasi R, Lisi L, Mancino G, Musiani M, Vázquez-Gómez L, Verlato E (2013) Oxidation of CO and CH4 on Pd-Fecralloy foam catalysts prepared by spontaneous deposition. Chem Eng J 230:422–431
Verlato E, Cattarin S, Comisso N, Gambirasi A, Musiani M, Vázquez-Gómez L (2012) Preparation of Pd-modified Ni foam electrodes and their use as anodes for the oxidation of alcohols in basic media. Electrocatal 3:48–58
Cimino S, Lisi L, Mancino G, Musiani M, Vázquez-Gómez L, Verlato E (2012) Catalytic partial oxidation of CH4-H2 mixtures over Ni foams modified with Rh and Pt. Int J Hydrogen Energy 37:17040–17051
Fiameni S, Herraiz-Cardona I, Musiani M, Pérez-Herranz V, Vázquez-Gómez L, Verlato E (2012) The HER in alkaline media on Pt-modified three-dimensional Ni cathodes. Int J Hydrogen Energy 37:10507–10516
Verlato E, Cattarin S, Comisso N, Mattarozzi L, Musiani M, Vázquez-Gómez L (2013) Reduction of nitrate ions at Rh-modified Ni foam electrodes. Electrocatal 4:203–211
Woods R (1976) Chemisorption at electrodes: hydrogen and oxygen on noble metals and their alloys. In: Bard AJ (ed) Electroanalytical chemistry. Marcel Dekker, New York, pp 1–162
Sattar MA, Conway BE (1969) Electrochemistry of the nickel-oxide electrode—VI. Surface oxidation of nickel anodes in alkaline solution. Electrochim Acta 14:695–710
Verlato E, Cattarin S, Comisso N, Mattarozzi L, Musiani M, Vázquez-Gómez L (2015) EIS study of the preparation of electrocatalysts through galvanic displacement reactions. J Electroanal Chem 737:100–107
Bianchini C, Shen PK (2009) Palladium-based electrocatalysts for alcohol oxidation in half cells and in direct alcohol fuel cells. Chem Rev 109:4183–4206
Trasatti S (1992) Electrocatalysis of hydrogen evolution: progress in cathode activation. In: Gerischer H, Tobias CW (eds) Advances in electrochemical science and engineering. VCH, Weinheim, pp 1–85
Rosca V, Duca M, de Groot MT, Koper MTM (2009) Nitrogen cycle electrocatalysis. Chem Rev 109:2209–2244
Pierozynski B, Mikolajczyk T, Turemko M (2015) On the temperature performance of ethanol oxidation reaction at palladium-activated nickel foam. Electrocatal 6:51–59
Vázquez-Gómez L, Cattarin S, Guerriero P, Musiani M (2008) Hydrogen evolution on porous Ni cathodes modified by spontaneous deposition of Ru or Ir. Electrochim Acta 53:8310–8318
Brylev O, Sarrazin M, Roué L, Bélanger D (2007) Nitrate and nitrite electrocatalytic reduction on Rh-modified pyrolytic graphite electrodes. Electrochim Acta 52:6237–6247
Mattarozzi L, Cattarin S, Comisso N, Guerriero P, Musiani M, Vázquez-Gómez L, Verlato E (2013) Electrochemical reduction of nitrate and nitrite in alkaline media at CuNi alloy electrodes. Electrochim Acta 89:488–496
Ribeiro FH, Chow M, Dalla Betta RA (1994) Kinetics of the complete oxidation of methane over supported palladium catalysts. J Catal 146:537–544
Cimino S, Mancino G, Lisi L (2013) Sulphur tolerance of a P-doped Rh/γ-Al2O3 catalyst during the partial oxidation of methane to syngas. Applied Catal B 138–139:342–352
Acknowledgments
The authors acknowledge the financial support of the Italian Ministry for Economic Development (MiSE-CNR Agreement on National Electrical System). They are indebted to Dr. Simona Barison and Dr. Paolo Guerriero, IENI CNR Padova, for recording SEM images.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Musiani, M., Cattarin, S., Cimino, S. et al. Preparation of 3D electrocatalysts and catalysts for gas-phase reactions, through electrodeposition or galvanic displacement. J Appl Electrochem 45, 715–725 (2015). https://doi.org/10.1007/s10800-015-0808-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10800-015-0808-1