Carbon xerogel-enhanced microchannel-structured beads for organic pollutants degradation: A novel catalyst for synergistic microscale process intensification

Abstract

A novel carbon xerogel-enhanced microchannel-structured alumina bead (3 mm in diameter, ACXx) was developed to enhance organic pollutant degradation in peroxymonosulfate (PMS)-activated advanced oxidation processes (AOPs). This catalyst design uniquely combines microstructure-enhanced diffusional transfer with material synergies. Cobalt-based active phases impregnated into a mesoporous carbon coating, prepared via sol-gel methods, increased the alumina bead's specific surface area by 14-fold, improving dispersion of 2 wt% Co3O4 (2Co/ACXx). The carbon coating provided complementary adsorptive and catalytic properties, significantly outperforming alumina beads lacking these synergies (e.g., those coated with mesoporous γ-Al2O3) or the pristine alumina bead, which relies solely on diffusional mass transfer through its bimodal pore structure. This study highlights the synergistic benefits of microstructural optimization and functional material integration in advancing heterogeneous catalytic efficiency. The approach offers a versatile framework for designing high-performance catalysts for AOPs and other applications requiring intensified mass transfer and reaction kinetics at microscales.