One step fabrication of SiC catalytic filter has a clear advantage in energy saving, but current approaches are limited by the mismatched calcination temperature between the SiC filter (&gt;1700 °C) and the catalysts (&lt;800 °C), as well as the difficulty in the chemical immobilization of catalysts. Here, a SrTi1-xCoxO3-SiC (STC-SiC) catalytic filter was directly fabricated at 1070 °C from raw SiC grains and STC precursor oxides (SrCO3, TiO2 and Co3O4) via a single-step reactive thermal processing (SRTP) approach. The novel SRTP approach enables the preparation of SiC filter and STC catalysts as well as the chemical immobilization of STC catalysts on SiC particles in a single step and at a significantly reduced sintering temperature (of 600 °C less than traditional approach). The SRTP approach has significantly reduced energy consumption of 59% and total fabrication time of 55% compared with the conventional method. An acid etching treatment was implemented for the STC-SiC catalytic filter (STC-SiC-A) to improve its catalytic performance through exposing the active Co3O4 and TiO2 nanoparticles on the surface of STC catalysts. The STC-SiC-A catalytic filter exhibits highly competitive NO oxidation of 61% and complete dust interception at 340 °C. The elevated redox capacity, more generated oxygen vacancies and enhanced gas adsorption performance are judged to be responsible for the superior performance of STC-SiC-A catalytic filter. This work demonstrates an efficient and rapid processing technique of SiC based catalytic filters which can also be implemented on other ceramic-based catalytic filters.

Readily processed multifunctional SiC catalytic filter for industrial emissions control

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