Solution Combustion Synthesis as intriguing technique to quickly produce performing catalysts for specific applications

Solution Combustion Synthesis (SCS) is becoming one of the most important ways to produce a wide range of advanced porous ceramic or metallic materials. These include ceramic oxide like nanostructured catalysts. SCS is an attractive alternative for the production of smart materials of high value compared to the more conventional and expensive preparation routes. SCS processes are characterized by relative medium heating oven temperatures (350–600°C), fast heating rates, short reaction times and very small residence time at high temperature. The final product is usually of high purity and well crystallized with nanometric size clusters. Furthermore, SCS, suitably adapted, is easily tunable to complex industrial supports to produce directly in situ structured catalysts. The present work deals with the analysis of low-environmental-impact premixed metal fiber burners (FeCrAlloy® fiber mat) for household applications. New catalytic burners based on Pd(LaMnO3·2ZrO2) catalyst were developed and tested in a partially modified commercial condensing boiler test rig fed with natural gas (NG). The catalytic burner presented a lower environmental impact, compared to the commercial bare burner, mainly in terms of CO. NO emissions were reduced, too, but in a slightly lower extent. The catalytic burner better stabilized the combustion process within the porous medium, maximizing the heat fraction transferred by radiation, cooling the flame temperature and enhancing the degree of completeness of NG combustion.