Catalytic Abatement of VOCs: Aerobic Combustion of Methane or Ethane over Alumina-Supported Metal Oxides Recovered from Spent Catalysts

γ-Al2O3 supported Cu, Cu-Zn and Cu-Ni-Fe-Zn oxide catalysts were prepared using leachate transition metal nitrate and sulfate aqueous solutions from commercial spent catalysts. A bench-scale rig was used to investigate the combustion activity of these catalysts toward methane or ethane in the air stream (1000 ppmv) at a space velocity of 20,000 h-1. The Cu-Ni-Fe-Zn oxides/γ-Al2O3 catalyst proved to be the most active catalyst for the combustion of methane in the temperature range 290-575°C and of ethane in the lower temperature range of 275-525oC as compared to Cu and Cu-Zn oxide loaded catalysts. X-ray powder diffractograms indicated that the metal oxide species were highly dispersed or amorphous on the alumina surface in all the catalysts except for the detection of a minority phase of monoclinic CuO on the Cu-containing mono-metallic catalysts. The co-existence of ZnO in the CuO catalysts suppresses the activity of the copper oxide species and, therefore, the conversion of methane or ethane was reduced. The present research endeavor provides proof-of-concept that relatively inexpensive metal oxide-based heterogeneous catalysts for VOCs abatement can be recovered from spent catalysts. Hence, environmental and health threats of improper handling of VOCs or spent catalysts may be alleviated.