High activity of a catalyst and its thermal stability over a lifetime are essential for catalytic applications, including catalytic gas sensors. Highly porous materials are attractive to support metal catalysts because they can carry a large quantity of well-dispersed metal nanoparticles, which are well-accessible for reactants. The present work investigates the long-term stability of mesoporous Co₃O₄-supported Au–Pd catalyst (Au–Pd@meso-Co₃O₄), with a metal loading of 7.5 wt% and catalytically active mesoporous Co₃O₄ (meso-Co₃O₄) for use in catalytic gas sensors. Both catalysts were characterized concerning their sensor response towards different concentrations of methane and propane (0.05–1%) at operating temperatures ranging from 200 °C to 400 °C for a duration of 400 h. The initially high sensor response of Au–Pd@meso-Co₃O₄ to methane and propane decreased significantly after a long-term operation, while the sensor response of meso-Co₃O₄ without metallic catalyst was less affected. Electron microscopy studies revealed that the hollow mesoporous structure of the Co₃O₄ support is lost in the presence of Au–Pd particles. Additionally, Ostwald ripening of Au–Pd nanoparticles was observed. The morphology of pure meso-Co₃O₄ was less altered. The low thermodynamical stability of mesoporous structure and low phase transformation temperature of Co₃O₄, as well as high metal loading, are parameters influencing the accelerated sintering and deactivation of Au–Pd@meso-Co₃O₄ catalyst. Despite its high catalytic activity, Au–Pd@meso-Co₃O₄ is not long-term stable at increased operating temperatures and is thus not well-suited for gas sensors.

It is shown that the operating temperature of pellistors for the detection of methane can be reduced to 300 °C by using Au–Pd nanoparticles on mesoporous cobalt oxide (Au–Pd@meso-Co₃O₄). The aim is to reduce possible catalyst poisoning that occurs during the high-temperature operation of conventional Pd-based pellistors, which are usually operated at 450 °C or higher. The individual role of Au–Pd as well as Co₃O₄ in terms of their catalytic activity has been investigated. Above 300 °C, Au–Pd bimetallic particles are mainly responsible for the catalytic combustion of methane. However, below 300 °C, only the Co₃O₄ has a catalytic effect. In contrast to methane, the sensor response and the temperature increase of the sensor under propane exposure is much larger than for methane due to the larger heat of combustion of propane. Due to its lower activation energy requirement, propane exhibits a higher propensity for oxidation compared to methane. As a result, the detection of propane can be achieved at even lower temperatures due to its enhanced reactivity.