Nickel foam based monolithic catalyst supporting transition metal oxides for toluene combustion: Experimental and theoretical study of interfacial synergistic oxidation and water resistance

Composite oxides obtained by calcining layered double hydroxides (LDHs) were used to construct a functional hydrolysis interface. Using nickel foam (NF) as a carrier, LDH was produced on the surface of this monolithic catalyst. The original morphology was retained after calcination. NF provided better thermal conductivity for catalytic combustion than conventional cordierite carriers. The clear phase interface between the different mixed metal oxides (CuxCo3-xFe-MMO/NF) promoted oxidation and hydrolysis during toluene combustion. Physicochemical investigations were performed using XRD, SEM, TEM, H2-TPR, ESR, and XPS. GC–MS, in situ DRIFT, H2O-TPD, and DFT were also used to explore the deep hydrolysis mechanism. The dissociation of water to form the surface *OH was the main hydrolysis process owing to the existence of the Cu-Co functional interface, with the largest energy emission (0.56 eV from DFT calculations). This hydrolysis process also altered the toluene degradation pathway, as confirmed by the in situ DRIFTS and GC/MS results, which guaranteed significant stability of the Cu1Co2Fe-MMO/NF catalyst in a highly humid environment and the removal efficiency and mineralization of toluene were both >90 % below 270 °C. This monolithic catalyst exhibits excellent water resistance and the toluene conversion rate remained stable at 90 % without any attenuationhas >40 h, which provides potential utility in the combustion of volatile organic compounds in high-humidity industrial streams.