The geometric surface area of capillary
microchannels is insufficient
for the direct deposition of a catalyst active phase to reach a sufficient
level of microreactor activity. For this reason it is necessary to
coat a porous layer of a catalyst support on the channel wall prior
to the deposition of the active metallic species. This work addresses
the challenges related to the preparation of well-adhered and uniform
silica coatings inside closed capillary channels suitable for catalyst
deposition for the direct synthesis of hydrogen peroxide. The method
used to deposit a layer of coating suspension, which upon solvent
evaporation and heating is transformed into a solid film, is known
as dynamic gas displacement. Variation of coating parameters and properties
of the coating solution could be used to produce microreactors coated
with different silica loadings. The most critical aspect of coating
is maintaining the film regularity during and after displacement of
the coating fluid. The uniformity of the coating thickness is greatly
affected not only by the ability to maintain the coating parameters
constant, such as the coating velocity, temperature, and solvent evaporation
rate during and after displacement of the coating solution, but also
by the rheological properties of the coating fluid. Advantages and
disadvantages of different coating techniques such as colloidal coating,
sol–gel, and slurry coating are discussed in detail. Finally,
we demonstrate that silica wall-coated layers with embedded Au–Pd
colloidal alloy nanoparticles are active in catalyzing the direct
synthesis of hydrogen peroxide.