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Chen Q, Tian E, Wang Y, Mo J, Xu G, Zhu M. Recent Progress and Perspectives of Direct Ink Writing Applications for Mass Transfer Enhancement in Gas-Phase Adsorption and Catalysis. SMALL METHODS 2023; 7:e2201302. [PMID: 36871146 DOI: 10.1002/smtd.202201302] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/10/2022] [Revised: 02/11/2023] [Indexed: 06/09/2023]
Abstract
Conventional adsorbents and catalysts shaped by granulation or extrusion have high pressure drop and poor flexibility for chemical, energy, and environmental processes. Direct ink writing (DIW), a kind of 3D printing, has evolved into a crucial technique for manufacturing scalable configurations of adsorbents and catalysts with satisfactory programmable automation, highly optional materials, and reliable construction. Particularly, DIW can generate specific morphologies required for excellent mass transfer kinetics, which is essential in gas-phase adsorption and catalysis. Here, DIW methodologies for mass transfer enhancement in gas-phase adsorption and catalysis, covering the raw materials, fabrication process, auxiliary optimization methods, and practical applications are comprehensively summarized. The prospects and challenges of DIW methodology in realizing good mass transfer kinetics are discussed. Ideal components with a gradient porosity, multi-material structure, and hierarchical morphology are proposed for future investigations.
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Affiliation(s)
- Qiwei Chen
- Department of Building Science, School of Architecture, Tsinghua University, Beijing, 100084, China
- Beijing Key Laboratory of Indoor Air Quality Evaluation and Control, Beijing, 100084, China
| | - Enze Tian
- Songshan Lake Materials Laboratory, Dongguan, 523808, China
- Institute of Physics, Chinese Academy of Sciences, Beijing, 100190, China
| | - Yan Wang
- Department of Building Science, School of Architecture, Tsinghua University, Beijing, 100084, China
- Beijing Key Laboratory of Indoor Air Quality Evaluation and Control, Beijing, 100084, China
| | - Jinhan Mo
- Department of Building Science, School of Architecture, Tsinghua University, Beijing, 100084, China
- Beijing Key Laboratory of Indoor Air Quality Evaluation and Control, Beijing, 100084, China
- Key Laboratory of Eco Planning & Green Building, Ministry of Education (Tsinghua University), Beijing, 100084, China
| | - Guiyin Xu
- State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, College of Materials Science and Engineering, Donghua University, Shanghai, 201620, China
| | - Meifang Zhu
- State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, College of Materials Science and Engineering, Donghua University, Shanghai, 201620, China
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2
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Otaola F, Mottelet S, Guénin E, Luart D, Leturia M. Additive manufacturing of microstructured reactors for organometallic catalytic reactions. LAB ON A CHIP 2023; 23:702-713. [PMID: 36412241 DOI: 10.1039/d2lc00816e] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/16/2023]
Abstract
The use of Additive Manufacturing for the fabrication of chemical reactors for flow chemistry is a promising field as it can lead to several improvements over more standard equipment. In this work, two different reactors were fabricated and compared: a Honeycomb monolith reactor with straight channels and a Periodic Open Cell Structure reactor. The Honeycomb monolith reactor was used as an example of a standard reactor (not necessarily additive manufactured) while the Periodic Open Cell Structure is a promising new type of reactor, which improves some key features, such as contact surface area and porosity. The two reactors were manufactured by Stereolithography technology with a high temperature resin and their internal surfaces were chemically activated by the grafting of palladium. For the surface activation, a two-step procedure was developed, firstly using NaOH and in a second step an aqueous solution of Na2PdCl4. After activation, a heterogeneous catalytic reaction was used to characterize the performance of the two fabricated reactors. The chosen reaction was the Suzuki-Miyaura reaction, which is commonly used in the pharmaceutical industry. The experimental results showed that, for equal contact surface area, the new designed reactor had better performance compared to the standard geometry.
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Affiliation(s)
- Franco Otaola
- ESCOM, TIMR (Integrated Transformations of Renewable Matter), Université de technologie de Compiègne, Centre de recherche Royallieu, CS 60319 - 6020, Compiègne Cedex, France.
| | - Stéphane Mottelet
- ESCOM, TIMR (Integrated Transformations of Renewable Matter), Université de technologie de Compiègne, Centre de recherche Royallieu, CS 60319 - 6020, Compiègne Cedex, France.
| | - Erwann Guénin
- ESCOM, TIMR (Integrated Transformations of Renewable Matter), Université de technologie de Compiègne, Centre de recherche Royallieu, CS 60319 - 6020, Compiègne Cedex, France.
| | - Denis Luart
- ESCOM, TIMR (Integrated Transformations of Renewable Matter), Université de technologie de Compiègne, Centre de recherche Royallieu, CS 60319 - 6020, Compiègne Cedex, France.
| | - Mikel Leturia
- ESCOM, TIMR (Integrated Transformations of Renewable Matter), Université de technologie de Compiègne, Centre de recherche Royallieu, CS 60319 - 6020, Compiègne Cedex, France.
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3
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McMillin RE, Clark B, Kay K, Gupton BF, Ferri JK. Customizing continuous chemistry and catalytic conversion for carbon–carbon cross-coupling with 3dP. INTERNATIONAL JOURNAL OF CHEMICAL REACTOR ENGINEERING 2022. [DOI: 10.1515/ijcre-2022-0117] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract
Support structures of various materials are used to enhance the performance of catalytic process chemistry. Typically, fixed bed supports contain regular channels enabling high throughput because of the low pressure drop that accompanies high flow rates. However, many fixed bed supports have a low surface-area-to-volume ratio resulting in poor contact between the substrates and catalyst. Three dimensional polymer printing (3dP) can be used to overcome these disadvantages by offering precise control over key design parameters of the fixed bed, including total bed surface area, as well as accommodating system integration features that are compatible with continuous flow chemistry. Additionally, 3dP allows for optimization of the catalytic process based on extrinsic constraints (e.g. operating pressure) and digital design features. These design parameters together with the physicochemical characterization and optimization of catalyst loading can be tuned to prepare customizable reactors based on objectives for substrate conversion and desired throughput. Using a Suzuki (carbon–carbon) cross-coupling reaction catalyzed by palladium, we demonstrate our integrated approach. We discuss key elements of our strategy including the rational design of hydrodynamics, immobilization of the heterogeneous catalyst, and substrate conversion. This hybrid digital-physical approach enables a range of pharmaceutical process chemistries spanning discovery to manufacturing scale.
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Affiliation(s)
- Robert E. McMillin
- Chemical and Life Science Engineering , Virginia Commonwealth University College of Engineering , Richmond , VA , 23284, USA
| | - Brian Clark
- Chemical and Life Science Engineering , Virginia Commonwealth University College of Engineering , Richmond , VA , 23284, USA
| | - Kaitlin Kay
- Chemical and Life Science Engineering , Virginia Commonwealth University College of Engineering , Richmond , VA , 23284, USA
| | - B. Frank Gupton
- Chemical and Life Science Engineering , Virginia Commonwealth University College of Engineering , Richmond , VA , 23284, USA
| | - James K. Ferri
- Chemical and Life Science Engineering , Virginia Commonwealth University College of Engineering , Richmond , VA , 23284, USA
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4
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Fonseca J, Gong T. Fabrication of metal-organic framework architectures with macroscopic size: A review. Coord Chem Rev 2022. [DOI: 10.1016/j.ccr.2022.214520] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/16/2023]
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5
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3D-printing design for continuous flow catalysis. TRENDS IN CHEMISTRY 2022. [DOI: 10.1016/j.trechm.2022.05.005] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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6
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Direct synthesis of HZSM-5 zeolites with enhanced catalytic performance in the methanol-to-propylene reaction. Catal Today 2022. [DOI: 10.1016/j.cattod.2022.04.023] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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7
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Han Q, Wang J, Li M, Wang X, Wang Q, Ye C, Yang C, Qiu T. A method to fabricate supported catalytic packing: Polydopamine as a "Double-Sided Adhesive" to prepare the fully covered seeding layer. J Taiwan Inst Chem Eng 2022. [DOI: 10.1016/j.jtice.2021.10.016] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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8
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Ding J, Huang X, Yang Q, Wang L, Peng Y, Li J, Huang J. Micro-structured Cu-ZSM-5 catalyst on aluminum microfibers for selective catalytic reduction of NO by ammonia. Catal Today 2022. [DOI: 10.1016/j.cattod.2021.05.013] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/24/2022]
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9
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Balzarotti R, Ambrosetti M, Beretta A, Groppi G, Tronconi E. Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study. FRONTIERS IN CHEMICAL ENGINEERING 2022. [DOI: 10.3389/fceng.2021.811439] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022] Open
Abstract
Structured catalysts are strong candidates for the intensification of non-adiabatic gas-solid catalytic processes thanks to their superior heat and mass transfer properties combined with low pressure drops. In the past two decades, different types of substrates have been proposed, including honeycomb monoliths, open-cell foams and, more recently, periodic open cellular structures produced by additive manufacturing methods. Among others, thermally conductive metallic cellular substrates have been extensively tested in heat-transfer limited exo- or endo-thermic processes in tubular reactors, demonstrating significant potential for process intensification. The catalytic activation of these geometries is critical: on one hand, these structures can be washcoated with a thin layer of catalytic active phase, but the resulting catalyst inventory is limited. More recently, an alternative approach has been proposed, which relies on packing the cavities of the metallic matrix with catalyst pellets. In this paper, an up-to-date overview of the aforementioned topics will be provided. After a brief introduction concerning the concept of structured catalysts based on highly conductive supports, specific attention will be devoted to the most recent advances in their manufacturing and in their catalytic activation. Finally, the application to the methane steam reforming process will be presented as a relevant case study of process intensification. The results from a comparison of three different reactor layouts (i.e. conventional packed bed, washcoated copper foams and packed copper foams) will highlight the benefits for the overall reformer performance resulting from the adoption of highly conductive structured internals.
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Abstract
During the last two decades, electrospinning has become a very popular technique for the fabrication of nanofibers due to its low cost and simple handling. Nanofiber materials have found utilization in many areas such as medicine, sensors, batteries, etc. In catalysis, these materials also present important advantages, since they present a low resistance to internal diffusion and a high surface area to volume ratio. These advantages are mainly due to the diameter–length proportion. A bibliographic analysis on the applications of electrospun nanofibers in catalysis shows that there are two important groups of catalysts that are being investigated, based on TiO2 and in carbon materials. The main applications found are in photo- and in electro-catalysis. The present study contributes by reviewing these catalytic applications of electrospun nanofibers and demonstrating that they are promising materials as catalysts, underlining some works to prove the advantages and possibilities that these materials have as catalysts. On one hand, the possibilities of synthesis are almost infinite, since with coaxial electrospinning quite complex nanofibers with different layers can be prepared. On the other hand, the diameter and other properties can be controlled by monitoring the applied voltage and other parameters during the synthesis, being quite reproducible procedures. The main advantages of these materials can be grouped in two: one related to their morphology, as has been commented, relative to their low resistance and internal diffusion, that is, their fluidynamic behavior in the reactor; the second group involves advantages related to the fact that the active phases can be nanoscaled and dispersed, improving the activity and selectivity in comparison with conventional catalytic materials with the same chemical composition.
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11
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Kundra M, Grall T, Ng D, Xie Z, Hornung CH. Continuous Flow Hydrogenation of Flavorings and Fragrances Using 3D-Printed Catalytic Static Mixers. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.0c05671] [Citation(s) in RCA: 14] [Impact Index Per Article: 4.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Milan Kundra
- CSIRO Manufacturing, Private Bag 10, Clayton South, Victoria 3169, Australia
| | - Tom Grall
- CSIRO Manufacturing, Private Bag 10, Clayton South, Victoria 3169, Australia
| | - Derrick Ng
- CSIRO Manufacturing, Private Bag 10, Clayton South, Victoria 3169, Australia
| | - Zongli Xie
- CSIRO Manufacturing, Private Bag 10, Clayton South, Victoria 3169, Australia
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Soliman A, AlAmoodi N, Karanikolos GN, Doumanidis CC, Polychronopoulou K. A Review on New 3-D Printed Materials' Geometries for Catalysis and Adsorption: Paradigms from Reforming Reactions and CO 2 Capture. NANOMATERIALS (BASEL, SWITZERLAND) 2020; 10:E2198. [PMID: 33158048 PMCID: PMC7693986 DOI: 10.3390/nano10112198] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/16/2020] [Revised: 10/24/2020] [Accepted: 10/26/2020] [Indexed: 01/15/2023]
Abstract
"Bottom-up" additive manufacturing (AM) is the technology whereby a digitally designed structure is built layer-by-layer, i.e., differently than by traditional manufacturing techniques based on subtractive manufacturing. AM, as exemplified by 3D printing, has gained significant importance for scientists, among others, in the fields of catalysis and separation. Undoubtedly, it constitutes an enabling pathway by which new complex, promising and innovative structures can be built. According to recent studies, 3D printing technologies have been utilized in enhancing the heat, mass transfer, adsorption capacity and surface area in CO2 adsorption and separation applications and catalytic reactions. However, intense work is needed in the field to address further challenges in dealing with the materials and metrological features of the structures involved. Although few studies have been performed, the promise is there for future research to decrease carbon emissions and footprint. This review provides an overview on how AM is linked to the chemistry of catalysis and separation with particular emphasis on reforming reactions and carbon adsorption and how efficient it could be in enhancing their performance.
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Affiliation(s)
- Ahmad Soliman
- Mechanical Engineering Department, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, UAE;
- Center for Catalysis and Separations, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, UAE; (N.A.); (G.N.K.)
| | - Nahla AlAmoodi
- Center for Catalysis and Separations, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, UAE; (N.A.); (G.N.K.)
- Chemical Engineering Department, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, UAE
| | - Georgios N. Karanikolos
- Center for Catalysis and Separations, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, UAE; (N.A.); (G.N.K.)
- Chemical Engineering Department, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, UAE
| | | | - Kyriaki Polychronopoulou
- Mechanical Engineering Department, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, UAE;
- Center for Catalysis and Separations, Khalifa University of Science and Technology, Abu Dhabi P.O. Box 127788, UAE; (N.A.); (G.N.K.)
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13
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McMillin RE, Luxon AR, Ferri JK. Enabling intensification of multiphase chemical processes with additive manufacturing. Adv Colloid Interface Sci 2020; 285:102294. [PMID: 33164781 DOI: 10.1016/j.cis.2020.102294] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2020] [Accepted: 10/13/2020] [Indexed: 12/18/2022]
Abstract
Fixed bed supports of various materials (metal, ceramic, polymer) and geometries are used to enhance the performance of many unit operations in chemical processes. Consider first metal and ceramic monolith support structures, which are typically extruded. Extruded monoliths contain regular, parallel channels enabling high throughput because of the low pressure drop accompanying high flow rate. However, extruded channels have a low surface-area-to-volume ratio resulting in low contact between the fluid phase and the support. Additive manufacturing, also referred to as three dimensional printing (3DP), can be used to overcome these disadvantages by offering precise control over key design parameters of the fixed bed including material-of-construction and total bed surface area, as well as accommodating system integration features compatible with continuous flow chemistry. These design parameters together with optimized extrinsic process conditions can be tuned to prepare customizable separation and reaction systems based on objectives for chemical process and/or the desired product. We discuss key elements of leveraging the flexibility of additive manufacturing to intensification with a focus on applications in continuous flow processes and disperse, multiphase systems enabling a range of scalable chemistry spanning discovery to manufacturing operations.
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14
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Bogdan E, Michorczyk P. 3D Printing in Heterogeneous Catalysis-The State of the Art. MATERIALS (BASEL, SWITZERLAND) 2020; 13:E4534. [PMID: 33066083 PMCID: PMC7601972 DOI: 10.3390/ma13204534] [Citation(s) in RCA: 19] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/17/2020] [Revised: 10/05/2020] [Accepted: 10/08/2020] [Indexed: 12/17/2022]
Abstract
This paper describes the process of additive manufacturing and a selection of three-dimensional (3D) printing methods which have applications in chemical synthesis, specifically for the production of monolithic catalysts. A review was conducted on reference literature for 3D printing applications in the field of catalysis. It was proven that 3D printing is a promising production method for catalysts.
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Affiliation(s)
- Elżbieta Bogdan
- Institute of Organic Chemistry and Technology, Faculty of Chemical Engineering and Technology, Cracow University of Technology, Warszawska 24, 31-155 Kraków, Poland;
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15
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Chen LH, Sun MH, Wang Z, Yang W, Xie Z, Su BL. Hierarchically Structured Zeolites: From Design to Application. Chem Rev 2020; 120:11194-11294. [DOI: 10.1021/acs.chemrev.0c00016] [Citation(s) in RCA: 158] [Impact Index Per Article: 39.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/21/2022]
Affiliation(s)
- Li-Hua Chen
- State Key Laboratory of Advanced Technology for Materials Synthesis and Processing, Wuhan University of Technology, 122 Luoshi Road, 430070 Wuhan, China
| | - Ming-Hui Sun
- State Key Laboratory of Advanced Technology for Materials Synthesis and Processing, Wuhan University of Technology, 122 Luoshi Road, 430070 Wuhan, China
- Laboratory of Inorganic Materials Chemistry, University of Namur, 61 rue de Bruxelles, B-5000 Namur, Belgium
| | - Zhao Wang
- State Key Laboratory of Advanced Technology for Materials Synthesis and Processing, Wuhan University of Technology, 122 Luoshi Road, 430070 Wuhan, China
| | - Weimin Yang
- State Key Laboratory of Green Chemical Engineering and Industrial Catalysis, Shanghai Research Institute of Petrochemical Technology, SINOPEC, Shanghai 201208, China
| | - Zaiku Xie
- State Key Laboratory of Green Chemical Engineering and Industrial Catalysis, Shanghai Research Institute of Petrochemical Technology, SINOPEC, Shanghai 201208, China
| | - Bao-Lian Su
- State Key Laboratory of Advanced Technology for Materials Synthesis and Processing, Wuhan University of Technology, 122 Luoshi Road, 430070 Wuhan, China
- Laboratory of Inorganic Materials Chemistry, University of Namur, 61 rue de Bruxelles, B-5000 Namur, Belgium
- Clare Hall, University of Cambridge, Cambridge CB2 1EW, United Kingdom
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16
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Sasaki H, Sakurai M. Proposal of Index for Reaction Improvement Using Structured Catalyst. JOURNAL OF CHEMICAL ENGINEERING OF JAPAN 2020. [DOI: 10.1252/jcej.19we108] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Hiromu Sasaki
- Department of Chemical Engineering, Tokyo University of Agriculture and Technology
| | - Makoto Sakurai
- Department of Chemical Engineering, Tokyo University of Agriculture and Technology
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17
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Enhancement of the Direct Synthesis of Dimethyl Ether (DME) from Synthesis Gas by Macro- and Microstructuring of the Catalytic Bed. Catalysts 2020. [DOI: 10.3390/catal10080852] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/11/2023] Open
Abstract
This work reports on a modelling study of the influence of the distribution of metallic and acidic active centers within a catalytic fixed-bed reactor for the direct synthesis of dimethyl ether (DME), conducted to demonstrate the potential of reactor-level and pellet-level structuring of catalytic active centers in process integration and intensification. To account for the pellet structure, the analysis was performed with the aid of a heterogeneous model considering both interphase and intrapellet mass transport resistances. The study evaluated, in terms of DME and methanol yield and selectivity, the performance of a tubular reactor loaded with a physical mixture of monofunctional catalyst pellets or structured bifunctional catalyst pellets with different arrangements of the catalytic centers. It was confirmed that bifunctional catalysts overperform significantly a physical mixture of monofunctional particles. Moreover, it was shown that the internal structure of a bifunctional catalyst pellet is an important feature that deserves to be exploited deeper, in view of further intensification of the DME synthesis process to be achieved with a better reactor design.
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18
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The Potential Use of Core-Shell Structured Spheres in a Packed-Bed DBD Plasma Reactor for CO2 Conversion. Catalysts 2020. [DOI: 10.3390/catal10050530] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
This work proposes to use core-shell structured spheres to evaluate whether it allows to individually optimize bulk and surface effects of a packing material, in order to optimize conversion and energy efficiency. Different core-shell materials have been prepared by spray coating, using dense spheres (as core) and powders (as shell) of SiO2, Al2O3, and BaTiO3. The materials are investigated for their performance in CO2 dissociation and compared against a benchmark consisting of a packed-bed reactor with the pure dense spheres, as well as an empty reactor. The results in terms of CO2 conversion and energy efficiency show various interactions between the core and shell material, depending on their combination. Al2O3 was found as the best core material under the applied conditions here, followed by BaTiO3 and SiO2, in agreement with their behaviour for the pure spheres. Applying a thin shell layer on the cores showed equal performance between the different shell materials. Increasing the layer thickness shifts this behaviour, and strong combination effects were observed depending on the specific material. Therefore, this method of core-shell spheres has the potential to allow tuning of the packing properties more closely to the application by designing an optimal combination of core and shell.
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19
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Zhou X, Liu CJ. Three-dimensional printing of porous carbon structures with tailorable pore sizes. Catal Today 2020. [DOI: 10.1016/j.cattod.2018.05.044] [Citation(s) in RCA: 19] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/01/2022]
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20
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Intensification of Catalytic Processes through the Pellet Structuring: Steady-State Properties of a Bifunctional Catalyst Pellet Applied to Generic Chemical Reactions and the Direct Synthesis of DME. Catalysts 2019. [DOI: 10.3390/catal9121020] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
Structuring of different types of catalytic active centers at a single-pellet level appears to be a promising and powerful tool for integration and intensification of multistep solid-catalyzed chemical reactions. However, the enhancement in the product yield and selectivity strongly depends on the proper choice of the distribution of different catalysts within the pellet. To demonstrate potential benefits from properly designed catalyst pellet, numerical studies were conducted with the aid of the mathematical model of a single spherical bifunctional catalyst pellet. The analysis was performed both for a system of two generic chemical reactions and for a real process, i.e., direct synthesis of dimethyl ether (DME) from synthesis gas via methanol. Evaluation of the pellet performance was done for three arrangements of the catalytic active sites within the pellet, i.e., a uniform distribution of two types of catalytic active centers in the entire volume of the pellet, and two core–shell structures. It was demonstrated that, especially for the larger pellets typical for fixed-bed applications, the product yield might be significantly improved by selecting proper catalyst arrangements within the pellet.
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Pretscher MO, Chen T, Sitaru G, Gekle S, Ji J, Agarwal S. Precise 2D-Patterned Incompatible Catalysts for Reactions in One-Pot. Chemistry 2019; 25:13640-13646. [PMID: 31415127 DOI: 10.1002/chem.201903486] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/30/2019] [Revised: 08/13/2019] [Indexed: 01/05/2023]
Abstract
Precise and direct two-dimensional (2D) printing of the incompatible polymer acid-base catalysts and their utility in one-pot two-step reactions were shown. Multistep catalytic reactions using incompatible catalysts in a one-pot reaction cascade requires special methods and materials to isolate the catalysts from each other. In general, this is a tedious process requiring special polymer architectures as the carrier for the catalysts to preserve the activity of otherwise incompatible catalysts. We propose the immobilization of incompatible polymer catalysts, such as polymer acid and base catalysts, on a substrate in variable sizes and amounts by precise 2D printing. The terpolymers with basic (4-vinylpyridine) and acidic (styrene sulfonic acid) functionalities and methacryloyl benzophenone as a UV cross-linking unit were used for 2D printing on poly(ethylene terephthalate) (PET). The printed meshes were immersed together in a reaction solution containing (dimethoxymethyl)benzene and ethyl cyanoformate, resulting in a two-step acid-base catalyzed cascade reaction; that is, deacetalization followed by carbon-building reaction. The time-dependent consumption of (dimethoxymethyl)benzene to the intermediate benzaldehyde and the product was monitored, and a kinetic model was developed to investigate the underlying reaction dynamics. The complexity of multistep Wolf-Lamb-type reactions was generally significantly decreased by using our approach because of the easy polymerization and immobilization procedure.
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Affiliation(s)
- Martin O Pretscher
- Macromolecular Chemistry II, Bavarian Polymer Institute, University of Bayreuth, Universitätsstrasse 30, 95440, Bayreuth, Germany
| | - Tingting Chen
- MOE Key Laboratory of Macromolecule Synthesis and Functionalization of Ministry of Education Department of Polymer Science and Engineering, Zhejiang University, Hangzhou, 310027, P.R. China
| | - Gabriel Sitaru
- Theoretical Physics VI, Biofluid Simulation and Modelling, University of Bayreuth, Universitätsstrasse 30, 95440, Bayreuth, Germany
| | - Stephan Gekle
- Theoretical Physics VI, Biofluid Simulation and Modelling, University of Bayreuth, Universitätsstrasse 30, 95440, Bayreuth, Germany
| | - Jian Ji
- MOE Key Laboratory of Macromolecule Synthesis and Functionalization of Ministry of Education Department of Polymer Science and Engineering, Zhejiang University, Hangzhou, 310027, P.R. China
| | - Seema Agarwal
- Macromolecular Chemistry II, Bavarian Polymer Institute, University of Bayreuth, Universitätsstrasse 30, 95440, Bayreuth, Germany
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22
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Ali MA, Ahmed S, Al-Baghli N, Malaibari Z, Abutaleb A, Yousef A. A Comprehensive Review Covering Conventional and Structured Catalysis for Methanol to Propylene Conversion. Catal Letters 2019. [DOI: 10.1007/s10562-019-02914-4] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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23
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24
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Potdar A, Thomassen LCJ, Kuhn S. Structured Porous Millireactors for Liquid‐Liquid Chemical Reactions. CHEM-ING-TECH 2019. [DOI: 10.1002/cite.201800128] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Aditi Potdar
- KU LeuvenDepartment of Chemical Engineering Celestijnenlaan 200F 3001 Leuven Belgium
| | - Leen C. J. Thomassen
- KU LeuvenDepartment of Chemical Engineering Celestijnenlaan 200F 3001 Leuven Belgium
- KU LeuvenFaculty of Industrial EngineeringLab4U Agoralaan building B box 8 3590 Diepenbeek Belgium
| | - Simon Kuhn
- KU LeuvenDepartment of Chemical Engineering Celestijnenlaan 200F 3001 Leuven Belgium
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Danaci S, Protasova L, Middelkoop V, Ray N, Jouve M, Bengaouer A, Marty P. Scaling up of 3D printed and Ni/Al2O3 coated reactors for CO2 methanation. REACT CHEM ENG 2019. [DOI: 10.1039/c9re00092e] [Citation(s) in RCA: 19] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
This study presents the innovative Ni/alumina coated structured metal supports manufactured by 3D-printing technique and their methane productivity comparison in two different experimental set-ups: a lab scale reactor and a mini-pilot scale reactor.
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Affiliation(s)
- Simge Danaci
- CEA, LITEN, DTBH, SCTR, LER
- F-38054 Grenoble
- France
- LEGI, Grenoble Alpes University/Grenoble-INP/CNRS, BP53
- Grenoble F-38051
| | - Lidia Protasova
- Flemish Institute for Technological Research - VITO
- B-2400 Mol
- Belgium
| | - Vesna Middelkoop
- Flemish Institute for Technological Research - VITO
- B-2400 Mol
- Belgium
| | - Nachiketa Ray
- KU Leuven
- Department of Materials Engineering
- B-3001 Heverlee
- Belgium
| | - Michel Jouve
- CEA, LITEN, DTBH, SCTR, LER
- F-38054 Grenoble
- France
| | | | - Philippe Marty
- CEA, LITEN, DTBH, SCTR, LER
- F-38054 Grenoble
- France
- LEGI, Grenoble Alpes University/Grenoble-INP/CNRS, BP53
- Grenoble F-38051
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Jiao Y, Ou X, Zhang J, Fan X. Structured ZSM-5 coated SiC foam catalysts for process intensification in catalytic cracking of n-hexane. REACT CHEM ENG 2019. [DOI: 10.1039/c8re00215k] [Citation(s) in RCA: 24] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
Structured zeolite/SiC foam catalysts provide alternative solutions to mass and heat transfer limited chemical transformations for process intensification, exemplified by cracking reactions.
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Affiliation(s)
- Yilai Jiao
- Shenyang National Laboratory for Materials Science
- Institute of Metal Research
- Chinese Academy of Sciences
- Shenyang 110016
- China
| | - Xiaoxia Ou
- School of Chemical Engineering and Analytical Science
- The University of Manchester
- Manchester
- UK
| | - Jinsong Zhang
- Shenyang National Laboratory for Materials Science
- Institute of Metal Research
- Chinese Academy of Sciences
- Shenyang 110016
- China
| | - Xiaolei Fan
- School of Chemical Engineering and Analytical Science
- The University of Manchester
- Manchester
- UK
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Liao Z, Xu T, Jiang Y, Jiang B, Wang J, Yang Y, Jiao Y, Yang Z, Zhang J. Methanol to Propylene over Foam SiC-Supported ZSM-5 Catalyst: Performance of Multiple Reaction–Regeneration Cycles. Ind Eng Chem Res 2018. [DOI: 10.1021/acs.iecr.8b02114] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
| | | | | | | | | | | | - Yilai Jiao
- Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, 72 Wenhua Road, Shenyang 110016, People’s Republic of China
| | - Zhenming Yang
- Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, 72 Wenhua Road, Shenyang 110016, People’s Republic of China
| | - Jinsong Zhang
- Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, 72 Wenhua Road, Shenyang 110016, People’s Republic of China
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High-performance thin-felt SS-fiber@HZSM-5 catalysts synthesized via seed-assisted vapor phase transport for methanol-to-propylene reaction: Effects of crystal size, mesoporosity and aluminum uniformity. J Catal 2018. [DOI: 10.1016/j.jcat.2018.01.025] [Citation(s) in RCA: 16] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/22/2022]
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Parra-Cabrera C, Achille C, Kuhn S, Ameloot R. 3D printing in chemical engineering and catalytic technology: structured catalysts, mixers and reactors. Chem Soc Rev 2018; 47:209-230. [PMID: 29131228 DOI: 10.1039/c7cs00631d] [Citation(s) in RCA: 162] [Impact Index Per Article: 27.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/03/2023]
Abstract
Computer-aided fabrication technologies combined with simulation and data processing approaches are changing our way of manufacturing and designing functional objects. Also in the field of catalytic technology and chemical engineering the impact of additive manufacturing, also referred to as 3D printing, is steadily increasing thanks to a rapidly decreasing equipment threshold. Although still in an early stage, the rapid and seamless transition between digital data and physical objects enabled by these fabrication tools will benefit both research and manufacture of reactors and structured catalysts. Additive manufacturing closes the gap between theory and experiment, by enabling accurate fabrication of geometries optimized through computational fluid dynamics and the experimental evaluation of their properties. This review highlights the research using 3D printing and computational modeling as digital tools for the design and fabrication of reactors and structured catalysts. The goal of this contribution is to stimulate interactions at the crossroads of chemistry and materials science on the one hand and digital fabrication and computational modeling on the other.
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Affiliation(s)
- Cesar Parra-Cabrera
- Centre for Surface Chemistry and Catalysis, KU Leuven - University of Leuven, Celestijnenlaan 200F, B-3001 Leuven, Belgium.
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Li X, Rezaei F, Rownaghi AA. 3D-printed zeolite monoliths with hierarchical porosity for selective methanol to light olefin reaction. REACT CHEM ENG 2018. [DOI: 10.1039/c8re00095f] [Citation(s) in RCA: 12] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
Abstract
Herein, we report the rapid synthesis of customized zeolite monoliths with various compositions and hierarchical porosity (macro–meso–micro) using a 3D printing technique.
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Affiliation(s)
- Xin Li
- Department of Chemical and Biochemical Engineering
- Missouri University of Science and Technology
- Rolla
- USA
| | - Fateme Rezaei
- Department of Chemical and Biochemical Engineering
- Missouri University of Science and Technology
- Rolla
- USA
| | - Ali A. Rownaghi
- Department of Chemical and Biochemical Engineering
- Missouri University of Science and Technology
- Rolla
- USA
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Manzano JS, Weinstein ZB, Sadow AD, Slowing II. Direct 3D Printing of Catalytically Active Structures. ACS Catal 2017. [DOI: 10.1021/acscatal.7b02111] [Citation(s) in RCA: 43] [Impact Index Per Article: 6.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/16/2022]
Affiliation(s)
- J. Sebastián Manzano
- U.S. Department of Energy, Ames Laboratory, Ames, Iowa 50011-3020, United States
- Department of Chemistry, Iowa State University, Ames, Iowa 50011-3111, United States
| | - Zachary B. Weinstein
- U.S. Department of Energy, Ames Laboratory, Ames, Iowa 50011-3020, United States
- Department of Chemistry, Iowa State University, Ames, Iowa 50011-3111, United States
| | - Aaron D. Sadow
- U.S. Department of Energy, Ames Laboratory, Ames, Iowa 50011-3020, United States
- Department of Chemistry, Iowa State University, Ames, Iowa 50011-3111, United States
| | - Igor I. Slowing
- U.S. Department of Energy, Ames Laboratory, Ames, Iowa 50011-3020, United States
- Department of Chemistry, Iowa State University, Ames, Iowa 50011-3111, United States
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Zhakeyev A, Wang P, Zhang L, Shu W, Wang H, Xuan J. Additive Manufacturing: Unlocking the Evolution of Energy Materials. ADVANCED SCIENCE (WEINHEIM, BADEN-WURTTEMBERG, GERMANY) 2017; 4:1700187. [PMID: 29051861 PMCID: PMC5644240 DOI: 10.1002/advs.201700187] [Citation(s) in RCA: 61] [Impact Index Per Article: 8.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/26/2017] [Revised: 05/22/2017] [Indexed: 05/18/2023]
Abstract
The global energy infrastructure is undergoing a drastic transformation towards renewable energy, posing huge challenges on the energy materials research, development and manufacturing. Additive manufacturing has shown its promise to change the way how future energy system can be designed and delivered. It offers capability in manufacturing complex 3D structures, with near-complete design freedom and high sustainability due to minimal use of materials and toxic chemicals. Recent literatures have reported that additive manufacturing could unlock the evolution of energy materials and chemistries with unprecedented performance in the way that could never be achieved by conventional manufacturing techniques. This comprehensive review will fill the gap in communicating on recent breakthroughs in additive manufacturing for energy material and device applications. It will underpin the discoveries on what 3D functional energy structures can be created without design constraints, which bespoke energy materials could be additively manufactured with customised solutions, and how the additively manufactured devices could be integrated into energy systems. This review will also highlight emerging and important applications in energy additive manufacturing, including fuel cells, batteries, hydrogen, solar cell as well as carbon capture and storage.
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Affiliation(s)
- Adilet Zhakeyev
- School of Engineering and Physical SciencesHeriot‐Watt UniversityEdinburghEH14 4ASUnited Kingdom
| | - Panfeng Wang
- School of Mechanical and Power EngineeringEast China University of Science and TechnologyShanghai200237China
| | - Li Zhang
- School of Mechanical and Power EngineeringEast China University of Science and TechnologyShanghai200237China
| | - Wenmiao Shu
- Department of Biomedical EngineeringUniversity of StrathclydeGlasgowG4 0NWUnited Kingdom
| | - Huizhi Wang
- School of Engineering and Physical SciencesHeriot‐Watt UniversityEdinburghEH14 4ASUnited Kingdom
| | - Jin Xuan
- School of Engineering and Physical SciencesHeriot‐Watt UniversityEdinburghEH14 4ASUnited Kingdom
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Hurt C, Brandt M, Priya SS, Bhatelia T, Patel J, Selvakannan PR, Bhargava S. Combining additive manufacturing and catalysis: a review. Catal Sci Technol 2017. [DOI: 10.1039/c7cy00615b] [Citation(s) in RCA: 72] [Impact Index Per Article: 10.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
Abstract
A review on additive manufacturing (AM) applied to heterogeneous catalysis reveals enabling power of AM and challenges to overcome in chemical interfacing and material printability.
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Affiliation(s)
- C. Hurt
- Centre for Additive Manufacturing
- RMIT University
- Australia
| | - M. Brandt
- Centre for Additive Manufacturing
- RMIT University
- Australia
| | - S. S. Priya
- Centre for Advanced Materials & Industrial Chemistry (CAMIC)
- RMIT University
- Australia
| | - T. Bhatelia
- CSIRO: Clayton Site
- Australia
- CSIRO Energy
- Kensington WA 6151
- Australia
| | | | - PR. Selvakannan
- Centre for Advanced Materials & Industrial Chemistry (CAMIC)
- RMIT University
- Australia
| | - S. Bhargava
- Centre for Advanced Materials & Industrial Chemistry (CAMIC)
- RMIT University
- Australia
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Potdar A, Protasova LN, Thomassen L, Kuhn S. Designed porous milli-scale reactors with enhanced interfacial mass transfer in two-phase flows. REACT CHEM ENG 2017. [DOI: 10.1039/c6re00185h] [Citation(s) in RCA: 17] [Impact Index Per Article: 2.4] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/19/2023]
Abstract
Designed porous milli-scale reactors with enhanced mass transfer performance and reduced pressure drop compared to conventional packed bed reactors.
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Affiliation(s)
- Aditi Potdar
- KU Leuven
- Department of Chemical Engineering
- 3001 Leuven
- Belgium
| | | | - Leen Thomassen
- KU Leuven
- Department of Chemical Engineering
- 3001 Leuven
- Belgium
- KU Leuven
| | - Simon Kuhn
- KU Leuven
- Department of Chemical Engineering
- 3001 Leuven
- Belgium
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Danaci S, Protasova L, Lefevere J, Bedel L, Guilet R, Marty P. Efficient CO 2 methanation over Ni/Al 2 O 3 coated structured catalysts. Catal Today 2016. [DOI: 10.1016/j.cattod.2016.04.019] [Citation(s) in RCA: 85] [Impact Index Per Article: 10.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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37
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Jiang Y, Wang Y, Zhao W, Huang J, Zhao Y, Yang G, Lei Y, Chu R. Effect of (Si+Al)/CTAB ratio on crystal size of mesoporous ZSM-5 structure over methanol-to-olefin reactions. J Taiwan Inst Chem Eng 2016. [DOI: 10.1016/j.jtice.2015.12.017] [Citation(s) in RCA: 18] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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Pérez-Uriarte P, Gamero M, Ateka A, Díaz M, Aguayo AT, Bilbao J. Effect of the Acidity of HZSM-5 Zeolite and the Binder in the DME Transformation to Olefins. Ind Eng Chem Res 2016. [DOI: 10.1021/acs.iecr.5b04477] [Citation(s) in RCA: 85] [Impact Index Per Article: 10.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Paula Pérez-Uriarte
- Department of Chemical Engineering, University of the Basque Country (UPV/EHU), P.O. Box 644, 48080, Bilbao, Spain
| | - Mónica Gamero
- Department of Chemical Engineering, University of the Basque Country (UPV/EHU), P.O. Box 644, 48080, Bilbao, Spain
| | - Ainara Ateka
- Department of Chemical Engineering, University of the Basque Country (UPV/EHU), P.O. Box 644, 48080, Bilbao, Spain
| | - Marta Díaz
- Department of Chemical Engineering, University of the Basque Country (UPV/EHU), P.O. Box 644, 48080, Bilbao, Spain
| | - Andrés T. Aguayo
- Department of Chemical Engineering, University of the Basque Country (UPV/EHU), P.O. Box 644, 48080, Bilbao, Spain
| | - Javier Bilbao
- Department of Chemical Engineering, University of the Basque Country (UPV/EHU), P.O. Box 644, 48080, Bilbao, Spain
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Tubío CR, Azuaje J, Escalante L, Coelho A, Guitián F, Sotelo E, Gil A. 3D printing of a heterogeneous copper-based catalyst. J Catal 2016. [DOI: 10.1016/j.jcat.2015.11.019] [Citation(s) in RCA: 117] [Impact Index Per Article: 14.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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Jiao Y, Yang X, Jiang C, Tian C, Yang Z, Zhang J. Hierarchical ZSM-5/SiC nano-whisker/SiC foam composites: Preparation and application in MTP reactions. J Catal 2015. [DOI: 10.1016/j.jcat.2015.09.002] [Citation(s) in RCA: 56] [Impact Index Per Article: 6.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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