Ceramic materials in monolithic honeycomb form offer the advantage of low pressure drop for automotive & stationary emissions control reactors, catalytic oxidation, adsorption, separation, and other applications. The ceramic materials can be extruded into cellular monoliths or coated onto a cellular ceramic substrate using conventional “washcoat” processes. Both extruded and coated ceramic substrates are prepared with a binder to promote interparticle adhesion and strength. For many applications it is advantageous to control pore structure, density, strength and surface area.
In this paper composition, fabrication and physical properties of cellular monolithic substrates will be reviewed. Emphasis will be on extruded materials used as catalytic supports for automotive, DeNOx and oxidation reactions.