Electrophoretically Al-coated wire mesh and its application for catalytic oxidation of 1,2-dichlorobenzene

Wire meshes coated with aluminum powder were developed using an electrophoretic deposition (EPD) method. A porous aluminum layer with a thickness of 100–120 μm can be attached on the wire surface after EPD and thermal treatment. Then additional calcination results in the formation of a thin Al2O3 layer in the outer surface of each deposited aluminum particle. The Al–Al2O3 coating layer is attached very strongly onto the wire surface due to partial sintering of deposited aluminum particles. A rectangular-shaped honeycomb module that has triangular channels was manufactured by packing alternately a flat sheet and a corrugated sheet of the coated wire mesh to a certain thickness. After a wash-coating of V2O5/TiO2 catalyst powder onto the wire surface of the honeycomb, the wire mesh honeycomb (WMH) catalyst was applied for catalytic oxidation of 1,2-dichlorobenzene (o-DCB). It shows better catalytic performance than the conventional ceramic honeycomb catalyst due to reduced mass transfer resistance by the existence of holes in the mesh sheet.