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Romero C, Liu Z, Wei Z, Fei L. A review of hierarchical porous carbon derived from various 3D printing techniques. NANOSCALE 2024; 16:12274-12286. [PMID: 38847575 DOI: 10.1039/d4nr00401a] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 07/05/2024]
Abstract
Hierarchical porous carbon is an area of advanced materials that plays a pivotal role in meeting the increasing demands across various industry sectors including catalysis, adsorption, and energy storage and conversion. Additive manufacturing is a promising technique to synthesize architectured porous carbon with exceptional design flexibility, guided by computer-aided precision. This review paper aims to provide an overview of porous carbon derived from various additive manufacturing techniques, including material extrusion, vat polymerization, and powder bed fusion. The respective advantages and limitations of these techniques will be examined. Some exemplary work on various applications will be showcased. Furthermore, perspectives on future research directions, opportunities, and challenges of additive manufacturing for porous carbon will also be offered.
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Affiliation(s)
- Cameron Romero
- Department of Chemical Engineering, University of Louisiana at Lafayette, USA.
| | - Zhi Liu
- Department of Chemical Engineering, University of Louisiana at Lafayette, USA.
| | - Zhen Wei
- Department of Chemical Engineering, University of Louisiana at Lafayette, USA.
| | - Ling Fei
- Department of Chemical Engineering, University of Louisiana at Lafayette, USA.
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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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Bonura G, Todaro S, Middelkoop V, de Vos Y, Abbenhuis H, Gerritsen G, Koekkoek A, Cannilla C, Frusteri F. Effectiveness of the 3D-printing procedure in the synthesis of hybrid catalysts for the direct hydrogenation of CO2 into dimethyl ether. J CO2 UTIL 2023. [DOI: 10.1016/j.jcou.2023.102458] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/15/2023]
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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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Catalytic Materials by 3D Printing: A Mini Review. Catalysts 2022. [DOI: 10.3390/catal12101081] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022] Open
Abstract
Catalytic processes are the dominant driving force in the chemical industry, proper design and fabrication of three-dimensional (3D) catalysts monoliths helps to keep the active species from scattering in the reaction flow, improve high mass loading, expose abundant active catalytic sites and even realize turbulent gas flow, greatly improving the catalytic performance. Three-dimensional printing technology, also known as additive manufacturing, provides free design and accurate fabrication of complex 3D structures in an efficient and economic way. This disruptive technology brings light to optimizing and promoting the development of existing catalysts. In this mini review, we firstly introduce various printing techniques which are applicable for fabricating catalysts. Then, the recent developments in 3D printing catalysts are scrutinized. Finally, challenges and possible research directions in this field are proposed, with the expectation of providing guidance for the promotion of 3D printed catalysts.
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Direct Ink 3D Printing of Porous Carbon Monoliths for Gas Separations. Molecules 2022; 27:molecules27175653. [PMID: 36080420 PMCID: PMC9457708 DOI: 10.3390/molecules27175653] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/26/2022] [Revised: 08/29/2022] [Accepted: 08/29/2022] [Indexed: 11/30/2022] Open
Abstract
Additive manufacturing or 3D printing is the advanced method of manufacturing monolithic adsorbent materials. Unlike beads or pellets, 3D monolithic adsorbents possess the advantages of widespread structural varieties, low heat and mass transfer resistance, and low channeling of fluids. Despite a large volume of research on 3D printing of adsorbents having been reported, such studies on porous carbons are highly limited. In this work, we have reported direct ink 3D printing of porous carbon; the ink consisted of commercial activated carbon, a gel of poly(4-vinylphenol) and Pluronic F127 as plasticizer, and bentonite as the binder. The 3D printing was performed in a commercial 3D printer that has been extensively modified in the lab. Upon 3D printing and carbonization, the resultant 3D printed porous carbon demonstrated a stable structure with a BET area of 400 m2/g and a total pore volume of 0.27 cm3/g. The isotherms of six pure-component gases, CO2, CH4, C2H6, N2, CO, and H2, were measured on this carbon monolith at 298 K and pressure up to 1 bar. The selectivity of four gas pairs, C2H6/CH4, CH4/N2, CO/H2, and CO2/N2, was calculated by Ideally Adsorbed Solution Theory (IAST) and reported. Ten continuous cycles of adsorption and desorption of CO2 on this carbon confirmed no loss of working capacity of the adsorbent.
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Clarkson CM, Wyckoff C, Parvulescu MJ, Rueschhoff LM, Dickerson MB. UV-assisted direct ink writing of Si3N4/SiC preceramic polymer suspensions. Ann Ital Chir 2022. [DOI: 10.1016/j.jeurceramsoc.2022.03.001] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/01/2022]
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Hu H, Ruan G, Jiang X, Pan H, Wu Z, Huang Y. Enhanced ethopabate adsorption in monodispersed porous carbon derived from zeolitic imidazolate framework-8. NEW J CHEM 2022. [DOI: 10.1039/d2nj00843b] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/18/2022]
Abstract
Drastically improved adsorption capacity for ethopabate is achieved by the partial carbonization of ZIF-8.
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Affiliation(s)
- Haoyun Hu
- Guangxi Colleges and Universities Key Laboratory of Food Safety and Detection, College of Chemistry and Bioengineering, Guilin University of Technology, Guilin 541004, Guangxi, China
| | - Guihua Ruan
- Guangxi Colleges and Universities Key Laboratory of Food Safety and Detection, College of Chemistry and Bioengineering, Guilin University of Technology, Guilin 541004, Guangxi, China
| | - Xiangqiong Jiang
- Guangxi Colleges and Universities Key Laboratory of Food Safety and Detection, College of Chemistry and Bioengineering, Guilin University of Technology, Guilin 541004, Guangxi, China
| | - Hong Pan
- Guangxi Colleges and Universities Key Laboratory of Food Safety and Detection, College of Chemistry and Bioengineering, Guilin University of Technology, Guilin 541004, Guangxi, China
| | - Zhuqiang Wu
- Guangxi Colleges and Universities Key Laboratory of Food Safety and Detection, College of Chemistry and Bioengineering, Guilin University of Technology, Guilin 541004, Guangxi, China
| | - Yipeng Huang
- Guangxi Colleges and Universities Key Laboratory of Food Safety and Detection, College of Chemistry and Bioengineering, Guilin University of Technology, Guilin 541004, Guangxi, China
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Lawson S, Li X, Thakkar H, Rownaghi AA, Rezaei F. Recent Advances in 3D Printing of Structured Materials for Adsorption and Catalysis Applications. Chem Rev 2021; 121:6246-6291. [PMID: 33947187 DOI: 10.1021/acs.chemrev.1c00060] [Citation(s) in RCA: 50] [Impact Index Per Article: 16.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/20/2022]
Abstract
Porous solids in the form of adsorbents and catalysts play a crucial role in various industrially important chemical, energy, and environmental processes. Formulating them into structured configurations is a key step toward their scale up and successful implementation at the industrial level. Additive manufacturing, also known as 3D printing, has emerged as an invaluable platform for shape engineering porous solids and fabricating scalable configurations for use in a wide variety of separation and reaction applications. However, formulating porous materials into self-standing configurations can dramatically affect their performance and consequently the efficiency of the process wherein they operate. Toward this end, various research groups around the world have investigated the formulation of porous adsorbents and catalysts into structured scaffolds with complex geometries that not only exhibit comparable or improved performance to that of their powder parents but also address the pressure drop and attrition issues of traditional configurations. In this comprehensive review, we summarize the recent advances and current challenges in the field of adsorption and catalysis to better guide the future directions in shape engineering solid materials with a better control on composition, structure, and properties of 3D-printed adsorbents and catalysts.
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Affiliation(s)
- Shane Lawson
- Department of Chemical & Biochemical Engineering, Missouri University of Science and Technology, Rolla, Missouri 65409-1230, United States
| | - Xin Li
- Department of Chemical & Biochemical Engineering, Missouri University of Science and Technology, Rolla, Missouri 65409-1230, United States
| | - Harshul Thakkar
- Department of Chemical & Biochemical Engineering, Missouri University of Science and Technology, Rolla, Missouri 65409-1230, United States
| | - Ali A Rownaghi
- Department of Chemical & Biochemical Engineering, Missouri University of Science and Technology, Rolla, Missouri 65409-1230, United States
| | - Fateme Rezaei
- Department of Chemical & Biochemical Engineering, Missouri University of Science and Technology, Rolla, Missouri 65409-1230, United States
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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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Shahbazi M, Jäger H. Current Status in the Utilization of Biobased Polymers for 3D Printing Process: A Systematic Review of the Materials, Processes, and Challenges. ACS APPLIED BIO MATERIALS 2021; 4:325-369. [PMID: 35014287 DOI: 10.1021/acsabm.0c01379] [Citation(s) in RCA: 47] [Impact Index Per Article: 15.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/11/2022]
Abstract
Three-dimensional (3D) printing is a revolutionary additive manufacturing technique that allows rapid prototyping of objects with intricate architectures. This Review covers the recent state-of-the-art of biopolymers (protein and carbohydrate-based materials) application in pharmaceutical, bioengineering, and food printing and main reinforcement approaches of biomacromolecular structure for the development of 3D constructs. Some perspectives and main important limitations with the biomaterials utilization for advanced 3D printing procedures are also provided. Because of the improved the ink's flow behavior and enhance the mechanical strength of resulting printed architectures, biopolymers are the most used materials for 3D printing applications. Biobased polymers by taking advantage of modifying the ink viscosity could improve the resolution of deposited layers, printing precision, and consequently, develop well-defined geometries. In this regard, the rheological properties of printable biopolymeric-based inks and factors affecting ink flow behavior related to structural properties of printed constructs are discussed. On the basis of successful applications of biopolymers in 3D printing, it is suggested that other biomacromolecules and nanoparticles combined with the matrix can be introduced into the ink dispersions to enhance the multifunctionality of 3D structures. Furthermore, tuning the biopolymer's structural properties offers the most common and essential approach to attain the printed architectures with precisely tailored geometry. We finish the Review by giving a viewpoint of the upcoming 3D printing process and recognize some of the existing bottlenecks facing the blossoming 3D pharmaceutical, bioengineering, and food printing applications.
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Affiliation(s)
- Mahdiyar Shahbazi
- Institute of Food Technology, University of Natural Resources and Life Sciences (BOKU), Muthgasse 18, 1190 Vienna, Austria
| | - Henry Jäger
- Institute of Food Technology, University of Natural Resources and Life Sciences (BOKU), Muthgasse 18, 1190 Vienna, Austria
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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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