3D printing as chemical reaction engineering booster

Zentel, Kristina Maria; Fassbender, M.; Pauer, Werner; Luinstra, Gerrit A.

doi:10.1016/bs.ache.2020.08.002

Cited by 22 publications

(20 citation statements)

References 89 publications

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“…substituting both Equations ( 18) and (19) in Equation ( 13), considering that the concentration of active sites, C L , is constant, and assuming that, the C HO − and C H+ are also constant in the reaction media, since water is used as unique solvent, the predicted phenol hydroxylation reaction rate results in the empirical predicted Equation ( 2):…”

Section: Reaction Mechanismmentioning

confidence: 99%

“…The additive manufacturing (AM), or three-dimensional (3D) printing technology, has been parallel developed to the MSR [15] in different sectors including aerospace, aeronautics and defense, medicine and healthcare, construction and chemical industry [15,16]. Currently, AM is shown as an efficient and sustainable tool for manufacturing novel catalysts and reactors [17][18][19][20][21][22]. In particular, the fabrication of 3D monolithic catalysts by using inks with catalytic materials, which implies that the catalytic active phase is included in the ink formulation, is a reality, and it has been demonstrated in liquid [23][24][25] and particularly in gas phase reactions [26][27][28].…”

Section: Introductionmentioning

confidence: 99%

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Monolithic Stirrer Reactors for the Sustainable Production of Dihydroxybenzenes over 3D Printed Fe/γ-Al2O3 Monoliths: Kinetic Modeling and CFD Simulation

et al. 2022

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The aim of this work is to evaluate the performance of the stirring 3D Fe/Al2O3 monolithic reactor in batch operation applied to the liquid-phase hydroxylation of phenol by hydrogen peroxide (H2O2). An experimental and numerical investigation was carried out at the following operating conditions: CPHENOL,0 = 0.33 M, CH2O2,0 = 0.33 M, T = 75–95 °C, P = 1 atm, ω = 200–500 rpm and WCAT ~ 1.1 g. The kinetic model described the consumption of the H2O2 by a zero-order power-law equation, while the phenol hydroxylation and catechol and hydroquinone production by Eley–Rideal model; the rate determining step was the reaction between the adsorbed H2O2, phenol in solution with two active sites involved. The 3D CFD model, coupling the conservation of mass, momentum and species together with the reaction kinetic equations, was experimentally validated. It demonstrated a laminar flow characterized by the presence of an annular zone located inside and surrounding the monoliths (u = 40–80 mm s−1) and a central vortex with very low velocities (u = 3.5–8 mm s−1). The simulation study showed the increasing phenol selectivity to dihydroxybenzenes by the reaction temperature, while the initial H2O2 concentration mainly affects the phenol conversion.

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Section: Reaction Mechanismmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Monolithic Stirrer Reactors for the Sustainable Production of Dihydroxybenzenes over 3D Printed Fe/γ-Al2O3 Monoliths: Kinetic Modeling and CFD Simulation

et al. 2022

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“…One of the reasons this is an interesting approach is that it can, amongst others, mitigate hot spots that are often found in conventional packed bed reactors. The literature already contains quite a number of excellent reviews on the potential of additive manufacturing for chemical engineering, but many of these publications tend to focus on the chemical aspect of the printing process (Bara et al, 2015;Zhou and Liu, 2017;Parra-Cabrera et al, 2018;Gupta et al, 2019b;Kotz et al, 2019;Gordeev and Ananikov, 2020;Zentel et al, 2020;Agrawaal and Thompson, 2021;Lawson et al, 2021b). This includes detailed studies and their considerable scope on the formulation of the printing ink, optimization of the printing process and assessment of the chemical and mechanical properties of the printed structures.…”

Section: Introductionmentioning

confidence: 99%

Review on Additive Manufacturing of Catalysts and Sorbents and the Potential for Process Intensification

Rosseau

Willemsen²,

Roghair

et al. 2022

Front. Chem. Eng.

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Additive manufacturing of catalyst and sorbent materials promises to unlock large design freedom in the structuring of these materials, and could be used to locally tune porosity, shape and resulting parameters throughout the reactor along both the axial and transverse coordinates. This contrasts catalyst structuring by conventional methods, which yields either very dense randomly packed beds or very open cellular structures. Different 3D-printing processes for catalytic and sorbent materials exist, and the selection of an appropriate process, taking into account compatible materials, porosity and resolution, may indeed enable unbounded options for geometries. In this review, recent efforts in the field of 3D-printing of catalyst and sorbent materials are discussed. It will be argued that these efforts, whilst promising, do not yet exploit the full potential of the technology, since most studies considered small structures that are very similar to structures that can be produced through conventional methods. In addition, these studies are mostly motivated by chemical and material considerations within the printing process, without explicitly striving for process intensification. To enable value-added application of 3D-printing in the chemical process industries, three crucial requirements for increased process intensification potential will be set out: i) the production of mechanically stable structures without binders; ii) the introduction of local variations throughout the structure; and iii) the use of multiple materials within one printed structure.

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“…Tailor made reactors have become readily accessible by additive manufacturing tools. Additive manufacturing has seen an extension of application over the last years, as various types of 3D printers in both "do-it-yourself" and industrial scale have become more affordable and give parts of satisfactory qualities [23].…”

Section: Introductionmentioning

confidence: 99%

“…In this method, heated polymer is extruded through a nozzle and deposited in layers. This allows to use the wide array of thermoplastic (crystalline) materials, such as PLA, PVA, Nylon and also PP [23]. FDM has been used for both fluidic Fig.…”

Section: Introductionmentioning

confidence: 99%

Optimization of a 3D-printed tubular reactor for free radical polymerization by CFD

2021

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A flow reactor for the complex reaction network of the free radical solution polymerization of n-butyl acrylate was optimized by a combination of kinetic modeling, computational fluid dynamics (CFD) and additive manufacturing. CFD was used to model a flow reactor with SMX mixing elements. An optimized geometry was 3D-printed from polypropylene. The modeled residence time behavior was compared to relevant experiments, giving a validation for the flow behavior of the reactor. A kinetic model for the free radical solution polymerization of n-butyl acrylate (BA) was in addition implemented into the CFD model. It was used to predict the polymerization behavior in the flow reactor and the resulting product properties. The experimental and computational results were in acceptable agreement. Graphical abstract

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3D printing as chemical reaction engineering booster

Cited by 22 publications

References 89 publications

Monolithic Stirrer Reactors for the Sustainable Production of Dihydroxybenzenes over 3D Printed Fe/γ-Al2O3 Monoliths: Kinetic Modeling and CFD Simulation

Monolithic Stirrer Reactors for the Sustainable Production of Dihydroxybenzenes over 3D Printed Fe/γ-Al2O3 Monoliths: Kinetic Modeling and CFD Simulation

Review on Additive Manufacturing of Catalysts and Sorbents and the Potential for Process Intensification

Optimization of a 3D-printed tubular reactor for free radical polymerization by CFD

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