Novel 3D-Printed Alumina Monolith Catalysts for Hydroconversion of Tar

Abstract

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.

Ceramic Foams with Controlled Geometries Through 3D‐Printed Sacrificial Templates

“…[ 67 ] Similarly, porous alumina (Al 2 O 3 ) monoliths with gyroid lattices were fabricated using 3D‐printed polymeric templates made from polylactic acid (PLA) and polyacrylonitrile butadiene styrene (ABS). [ 68 ] Various loading methods were investigated for creating 3D ordered macroporous monoliths, employing a polymethyl methacrylate (PMMA) sacrificial template prepared via the constant temperature suspension film‐forming method. [ 33 ] Digital light processing (DLP) techniques were employed for the production of geometry‐controlled monolithic composites using a polymeric 3D‐printed template, [ 69 ] as well as ceramic monoliths through a replication method using a resin template.…”