Fabrication and Evaluation of Particulate Matter Purification Filter Using Plasma-Sprayed Catalyst Film on SUS316 Mesh

We prepared a catalyst-coated wire-mesh filter by thermal plasma spray method in order to develop a new type of carbon soot particulate matter (PM) removal component. The halftone plate of a 316 stainless steel (SUS316) mesh was newly used as a substrate for a PM oxidation catalyst. A thermal plasma-spray method was applied to form a Ni-Pd alloy catalytic layer on the filter. As for the performance of Ni-Pd supported filter, the PM oxidation started from approximately 420°C, and the combustion at the catalytic surface took place at around 500–540°C, and finally a noncatalytic oxidation proceeded at around 650°C. The catalyst lowered a peak temperature around 110–220°C than that of only PM. Furthermore, the catalytic performance was maintained after a 5 times-repeated PM oxidation test. By the characterization of the catalyst layer, it was found that Pd particles were dispersed in a matrix of Ni and segregated on the surface and upper part of the plasma-sprayed film on the wire. The surface morphology did not change after the repeated cycle test. In this study, we found the availability of the plasma-spray catalyzed mesh filter was fabricated and as an environmental material with PM removal catalytic function.