Ceramic Catalysts: What Are They and How Are They Used in Industry?

By Ibtisam AbbasiReviewed by Lexie CornerApr 29 2025

Catalysts are substances that speed up chemical reactions or allow them to occur at lower temperatures or pressures.¹ When catalysts are used to control and enhance reactions, the process is called catalysis.

Heterogeneous catalysis, where the catalyst is in a different phase than the reactants, is critical for advancing green chemistry and supporting the shift toward carbon-neutral industrial processes.² Within this area, ceramic catalysts have emerged as important materials.

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What Is a Ceramic Catalyst?

Solid catalysts are widely used in heterogeneous catalysis, and ceramics are a common material choice. In a heterogeneous reaction, the catalyst is in a different phase from the reactants, and the reaction takes place at the catalyst’s surface.

Ceramic materials can serve either as active catalysts themselves or as supports for metals or metal oxides. In many industrial applications, ceramic catalysts are complex metal oxides that incorporate two or more different cations to improve reaction rates.³

Ceramic catalysts are often produced by depositing an active catalytic phase onto a ceramic support. These supports can take various forms, including granular, cylindrical, ring-shaped, or tubular designs with multiple holes, as well as monolithic structures with honeycomb or cellular geometries.

Manufacturing typically involves pressing or extruding a plastic mass into the desired shape, followed by drying and firing at high temperatures. This process results in materials with the necessary combination of thermal and mechanical strength, high porosity, chemical resistance, and long-term structural stability.⁴

Industrial Applications of Ceramic Catalysts

Automotive: Ceramic Catalytic Converters

Ceramic catalytic converter technology was first introduced in the U.S. in 1975 to help reduce harmful emissions from automobiles, following new regulations set by the U.S. Environmental Protection Agency (EPA). Ceramics were chosen for these applications due to their low thermal inertia, high heat resistance, excellent thermal shock tolerance, and oxidation resistance.⁵

In one comparative study, researchers evaluated the performance of a ceramic catalytic converter (CATCO) against a metallic catalytic converter made from FeCrAl alloy. A gasoline-powered Mitsubishi 4G93 engine, fueled with RON 95 gasoline, was fitted with both types of converters to assess their impact on exhaust emissions.

When comparing emissions performance, the ceramic catalytic converter achieved the highest conversion efficiency for carbon monoxide (CO). At a 10 % engine load and a speed of 1000 rpm, it reached nearly 97 % CO conversion. It also performed well for hydrocarbon (HC) emissions, achieving a conversion efficiency of 97.8 % under the same conditions.

However, for nitrogen oxide (NOₓ) emissions, the metallic catalytic converter demonstrated higher efficiency. Overall, the results showed that ceramic catalytic converters are highly effective at reducing CO and HC emissions, supporting their continued use in emissions control for automotive applications.⁶

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Ceramic Catalysts for Oxidation Reactions

Catalytic total oxidation is a key method for reducing air pollution, particularly by breaking down volatile organic compounds (VOCs) into less harmful substances. Ceramic catalysts are often used to support these reactions due to their thermal stability and durability.

In a study published in Fuel Communications, researchers evaluated the performance of a ceramic catalyst filter medium for the oxidation of CO and VOCs, as well as the reduction of nitrogen dioxide NO₂. The ceramic catalysts were prepared using a wet impregnation method and tested inside a stainless steel reactor with a 10 cm diameter and 150 cm height.

The experiments showed that increasing catalyst loading significantly improved CO oxidation rates. The highest catalytic activity, achieving over 93 % CO removal, was observed at 290 °C for 1 vol.% CO at lower catalyst loading and 3 vol.% CO at higher loading.

Long-term stability tests demonstrated that complete CO conversion could be maintained at 390 °C for at least 100 hours without noticeable catalyst deactivation.

For VOC removal, the ceramic catalyst achieved peak activity, around 90 % conversion, within the 350–420 °C temperature range.⁷ These results show that ceramic catalysts can maintain high oxidation activity and long-term operational stability.

Ceramic Catalysts for Air Purification

Air pollution remains a major concern globally, with particulate matter (PM) and VOCs posing significant risks to human health. Conventional disposable air filters are widely used in industry, but their frequent replacement requirements and associated waste have driven the search for more sustainable alternatives.

Researchers have recently developed water-washable, regenerable ceramic catalyst filters (CCFs) designed to efficiently remove air pollutants.

These CCFs feature a dual-function architecture: particulate matter is captured in the inlet channel of the ceramic structure, while VOC gases are broken down by a photocatalyst coating on the outlet channel. This design allows a single unit to simultaneously remove multiple types of pollutants.

The CCFs achieved a PM removal efficiency of 95 % and a VOC removal efficiency of 82 %, all in a single pass. The filters were engineered with an inorganic membrane coating the inner channels and a Cu₂O / TiO₂ photocatalyst applied to the outer channels.

Compared to conventional air filters, which typically hold around 5 g/L of dust, the CCFs demonstrated a fourfold increase in dust-loading capacity, reaching approximately 20 g/L. The CCFs could be regenerated up to ten times through simple water washing without any significant loss in filtration performance.

Researchers estimate the operational lifespan of these filters could reach up to 20 years, far exceeding the six-month lifespan typical of traditional disposable filters.⁸ These results highlight how ceramic catalyst filters offer a durable, low-maintenance solution for both indoor and outdoor air purification, supporting efforts toward carbon-neutral and sustainable industrial operations.

What's Next for Ceramic Catalysts?

Ceramic catalysts are increasingly seen as key components in the advancement of green chemistry and sustainable industrial technologies. They are being used in fuel cells, reactors, and other energy systems that aim to reduce environmental impact.

Emerging areas of research include ceramic nanofiber-based catalysts, which offer unique surface properties and improved efficiency for oxidative reactions. In addition, advances in 3D printing are enabling the fabrication of complex ceramic structures and tailored support materials, opening new possibilities for catalyst design and performance.

As these technologies mature, ceramic catalysts are expected to be central in supporting carbon-neutral industrial processes and next-generation energy solutions. To stay ahead in catalyst innovation, visit:

• A Highly Efficient and Stable Catalyst for Acidic Oxygen Evolution
• Real-Time View of Catalyst Transformation During Operation
• Innovative Catalyst Design Overcomes Long-Standing Bottlenecks in Water Splitting
• Cu2O Catalysts and the Future of Ammonia Production

References and Further Reading

1. U.S Department of Energy (2025). DOE Explains...Catalysts. [Online]. Available at: https://www.energy.gov/science/doe-explainscatalysts [Accessed on: April 20, 2025].
2. Friend, C. et. al. (2017). Heterogeneous catalysis: a central science for a sustainable future. Accounts of chemical research, 50(3), 517-521. Available at: https://doi.org/10.1021/acs.accounts.6b00510
3. Keane, M. (2003). Ceramics for Catalysis. Journal of Materials Sciences. 38. 4661-4675. Available at: https://www.eng.uc.edu/~beaucag/Research/050913_ArgonneWorkshop/CatalysisReviews/ZeoliteUK2003Review.pdf
4. Medvedovskii, E. et. al. (1992). Ceramic catalyst supports and catalysts for chemical processes and scrubbing of gas discharges. Glass and ceramics, 49(1), 5-9. Available at: https://doi.org/10.1007/BF00676665
5. Gulati, S. T. (1991). Ceramic converter technology for automotive emissions control. SAE transactions. 911736. e-ISSN: 2688-3627. 529-544. Available at: https://doi.org/10.4271/911736
6. Feriyanto, D. et. al. (2020). Comparison of metallic (FeCrAl) and Ceramic Catalytic Converter (CATCO) in reducing exhaust gas emission of gasoline engine fuelled by RON 95 to develop health environment. In IOP Conference Series: Earth and Environmental Science. 485(1). 012004. IOP Publishing. Available at: https://www.doi.org/10.1088/1755-1315/485/1/012004
7. Straczewski, G. et. al. (2021). Total oxidation of carbon monoxide, VOC and reduction of NO2 with catalytic ceramic filter media. Fuel Communications, 9, 100038. Available at: https://doi.org/10.1016/j.jfueco.2021.100038
8. Kwon, H. et al. (2023). Long-lifetime water-washable ceramic catalyst filter for air purification. Nat Commun 14, 520. Available at: https://doi.org/10.1038/s41467-023-36050-w

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