3D-printing of metallic honeycomb monoliths as a doorway to a new generation of catalytic devices: the Ni-based catalysts in methane dry reforming showcase

Stainless-steel honeycomb monoliths (square cell-shape/230 cpsi cylinders) were 3D-printed and used as support of a Ni/CeO2-ZrO2 powder deposited by washcoating. The resulting catalysts were characterized by XRF, SEM-EDX and H-2-TPR, and tested in the dry reforming of methane reaction. In the 750-900 degrees C range, they showed competitive conversions (45-95%) and H-2/CO ratio (0.84-0.94) compared to cordierite honeycombs with same catalyst loading and geometric characteristics, but did not require activation time thanks to better heat transfer. Both structured catalysts were stable in prolonged TOS experiments. The bare metallic monoliths exhibited significant activity at 900 degrees C due to their intrinsic nickel content.

Automated summary

In this study, stainless-steel honeycomb monoliths were fabricated using 3D printing and used as catalyst supports for Ni/CeO2-ZrO2 powder. The resulting catalysts showed competitive conversions and H-2/CO ratios in the dry reforming of methane reaction without requiring activation time, thanks to better heat transfer. Comparison with cordierite honeycombs revealed the superior performance of the structured catalysts.