FeCrAl as a Catalyst Support

The iron-chromium-aluminum alloy (FeCrAl) is an exceptional support for highly exothermic and endothermic reactions that operate above 700 °C in chemically aggressive environments, where low heat and mass transfer rates limit reaction yield. FeCrAl two- and three-dimensional structured networks - monoliths, foams, and fibers - maximize mass transfer rates, while their remarkable thermal conductivity minimizes hot spots and thermal gradients. Another advantage of the open FeCrAl structure is the low pressure drop due to the high void fraction and regularity of the internal path. The surface Al2O3 layer, formed after an initial thermal oxidation, supports a wide range of metal and metal oxide active phases. The aluminum oxide that adheres to the metal surface protects it from corrosive atmospheres and carbon (carburization), thus allowing FeCrAl to operate at a higher temperature. The top applications are industrial burners, in which compact knitted metal fibers distribute heat over large surface areas, and automotive tail gas converters. Future applications include producing H2 and syngas from remote natural gas in modular units. This Review summarizes the specific preparation techniques, details process operating conditions and catalyst performance of several classes of reactions, and highlights positive and challenging aspects of FeCrAl.