Both flat and corrugated wire mesh sheets were coated with aluminum powder by using electrophoretic deposition (EPD) method. Controlled thermal sintering of coated samples yielded uniform porous aluminum layer with a thickness of 100 μm that was attached firmly on the wire meshes. Subsequent controlled calcination formed a finite thickness of Al2O3 layer on the outer surface of each deposited aluminum particles, which resulted in the formation of Al2O3/Al double-layered composite particles that were attached firmly on the wire surface to form a certain thickness of porous layer. A rectangular-shaped wire-mesh honeycomb (WMH) module with triangular-shaped channels was manufactured by packing alternately the flat sheet and corrugated sheet of the Al2O3/Al-coated wire meshes. This WMH was further coated with V2O5-MoO3-WO3 catalyst by wash-coating method to be applied for the selective catalytic reduction (SCR) of NO with NH3. With an optimized catalyst loading of 16 wt%, WMH catalyst module shows more than 90% NO conversion at 240 ℃ and almost complete NO conversion at temperatures higher than 300 ℃ at GHSV 5,000 h.1. When compared with conventional ceramic honeycomb catalyst, WMH catalyst gives NO conversion higher by 20% due to reduced mass transfer resistance by the existence of three dimensional opening holes in WMH.

EPD Method Al/Al2O3 Layer WMH SCR of NO NH3 V2O5-WO3/TiO2 Catalyst

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