This paper reports on a novel method for the preparation of monolith catalysts using a 3D-printed matrix. The development included an investigation into potential approaches to improving the strength of alumina catalysts, 3D printing of a polymer matrix (template) with a specific channel structure, preparation of templated monolith catalysts, an examination of their physicochemical properties, and testing of these catalysts in hydroconversion of tar. Using an indirect template method, this study is the first to prepare a Al2O3 monolith catalyst with a Schwartz surface microstructure. The extrudate drying rate was found to be the most important parameter for the synthesis of high-strength catalysts. The activity of the monolith catalyst proved to be comparable—and in some parameters even markedly superior—to that of similar granular samples. The tar hydroconversion product consisted of super heavy oil with 2.8 wt % of sulfur.

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