Optimal microstructural design of a catalytic premixed FeCrAlloy fiber burner for methane combustion

New catalytic FeCrAlloy premixed fiber burners for natural gas combustion in domestic applications were developed according to an accurate microstructural design consisting of subsequent optimized steps: (i) optimal preoxidation of the FeCrAlloy fiber mat so as to develop the best possible Al2O3 layer for simultaneous prevention of deeper fiber oxidation at high temperature and optimal catalyst anchoring over the fiber surface, (ii) deposition via the either spray-pyrolysis or wash-coating technique of a previously developed perovskite catalyst (LaMnO3. 17MgO), and (iii) extensive testing of the catalyst-burner bonding strength and burner performance. Even after extensive aging under practical operating conditions (repeated on-off cycles and prolonged durations under high-temperature radiating conditions), the best developed burners (i.e., those obtained by spray pyrolysis) exhibit very limited catalyst loss and still remarkably lower (30-50%) NO and CO emissions than noncatalytic, virgin FeCrAlloy burners at the specific power densities of practical interest (150-650 kW/m(2)).