Preparation and characterisation of carbon-coated monoliths for catalyst supports Original Research Article

Carbon coated monoliths have been prepared by dipcoating cordierite monoliths in a polymer mixture and subsequent carbonisation and activation. Preparation parameters that were varied were viscosity of the dipcoating mixture, carbon precursor and carbonisation temperature. Two different polymers have been used as carbon precursors, Novolac and Furan resins. Also monoliths have been coated with slurry of these resins and a commercial activated carbon, CP-97. The features of the final carbon that have been optimised are carbon loading, carbon layer thickness, coverage and mesoporosity. Coverage has been tested by leaching tests in acid media and SEM analysis. Both coverage and mesoporosity are considerably enhanced when the dipcoating mixture was a slurry of Furan resin and activated carbon. Leaching of the cordierite was considerably reduced but not completely eliminated. The morphology of the activated carbon could be transferred to the coating layer.