High Performance Tunable Catalysts Prepared by Using 3D Printing

Honeycomb monoliths are the preferred supports in many industrial heterogeneous catalysis reactions, but current extrusion synthesis only allows obtaining parallel channels. Here, we demonstrate that 3D printing opens new design possibilities that outperform conventional catalysts. High performance carbon integral monoliths have been prepared with a complex network of interconnected channels and have been tested for carbon dioxide hydrogenation to methane after loading a Ni/CeO2 active phase. CO2 methanation rate is enhanced by 25% at 300 degrees C because the novel design forces turbulent flow into the channels network. The methodology and monoliths developed can be applied to other heterogeneous catalysis reactions, and open new synthesis options based on 3D printing to manufacture tailored heterogeneous catalysts.

Automated summary

Researchers have demonstrated that 3D printing allows for the creation of high-performance carbon integral monoliths with a complex network of interconnected channels, outperforming conventional catalysts in heterogeneous catalysis reactions. This novel design enhances the CO2 methanation rate by 25% at 300 degrees C due to the forced turbulent flow into the channels network, opening up new synthesis options for tailored heterogeneous catalysts.