CO2 valorisation to methane on highly stable iron impregnated ceria-zirconia based 3D-printed catalyst

The catalytic activity of 3D-printed metal monoliths loaded with iron impregnated ceria-zirconia mixed-oxide support on CO2 conversion to methane was investigated between 300 and 500 °C under 1 bar and 20 bar pressure. The catalyst was characterised using TPR, XRD, SEM-EDX and in-situ DRIFTS. At 400 °C and atmospheric pressure, the catalyst wash-coated monoliths increased the methane yield by 3.5 times and doubled the CO2 conversion compared to the same catalyst dispersed as a powder. Methane selectivity of 95.2% was obtained at 400 °C and 20 bars pressure. This is the highest methane selectivity recorded in the literature for CO2 methanation using an iron catalyst. The catalyst loaded monoliths were stable over a continuous operation of 100 h at 500 °C and 20 bar. Such increased methane selectivity and yield combined with a long duration stability as well as an economic and easier synthesis process vouches for the great potential of catalyst loaded 3D monoliths for industrial application.