Development of Catalytically Functionalized Polyester-Based Filters Produced by Flame Spray Pyrolysis

For industrial processes—like waste incineration—it is necessary to reduce solid components (like dust or fly ash) as well as gaseous components (like dioxins, CO and other harmful hydrocarbons) to fulfill legal requirements. Therefore, catalytically functionalized filters based on polymers already exist. However, it is known that such filters are always constructed in multiple layers to prevent the migration of catalyst particles. This study demonstrates that it is possible to prepare a stable catalytic functionalized single-layer filter based on polyester needle felt by using flame spray pyrolysis. The catalyst is a low temperature active Pt/TiO₂ with a loading weight of 38 g/l on the filter. Via SEM images the uniform distribution of the catalytic particles even in the deeper regions of the single-layer filter was proven. The structure was confirmed after experiments under realistic conditions—migration could not be obtained. Likewise, it was obtained that the oxidative conversion of carbon monoxide (CO) to carbon dioxide (CO₂) is completely even at temperatures below 100 °C. Furthermore, comparative studies with catalysts on a honeycomb and a ceramic foam have shown that the conversion on the polyester needle felt textile catalyst is comparable.