Combined dip-coating/spin-coating depositions on ceramic honeycomb monoliths for structured catalysts preparation

Stable Loading of TiO2 Catalysts on the Surface of Metal Substrate for Enhanced Photocatalytic Toluene Oxidation

To promote the practical application of TiO2 in photocatalytic toluene oxidation, the honeycomb aluminum plates were selected as the metal substrate for the loading of TiO2 powder. Surface-etching treatment was performed and titanium tetrachloride was selected as the binder to strengthen the loading stability. The loading stability and photocatalytic activity of the monolithic catalyst were further investigated, and the optimal surface treatment scheme (acid etching with 15.0 wt.% HNO3 solution for 15 min impregnation) was proposed. Therein, the optimal monolithic catalyst could achieve the loading efficiency of 42.4% and toluene degradation efficiencies of 76.2%. The mechanism for the stable loading of TiO2 was revealed by experiment and DFT calculation. The high surface roughness of metal substrate and the strong chemisorption between TiO2 and TiCl4 accounted for the high loading efficiency and photocatalytic activity. This work provides the pioneering exploration for the practical application of TiO2 catalysts loaded on the surface of metal substrate for VOCs removal, which is of significance for the large-scaled application of photocatalytic technology.

The Thickness and Structure of Dip-Coated Polymer Films in the Liquid and Solid States

Films formed by dip coating brass wires with dilute and semi-dilute solutions of polyvinyl butyral in benzyl alcohol were studied in their liquid and solid states. While dilute and semi-dilute solutions behaved as Maxwell viscoelastic fluids, the thickness of the liquid films followed the Landau-Levich-Derjaguin prediction for Newtonian fluids. At a very slow rate of coating, the film thickness was difficult to evaluate. Therefore, the dynamic contact angle was studied in detail. We discovered that polymer additives preserve the advancing contact angle at its static value while the receding contact angle follows the Cox–Voinov theory. In contrast, the thickness of solid films does not correlate with the Landau-Levich-Derjaguin predictions. Only solutions of high-molecular-weight polymers form smooth solid films. Solutions of low-molecular-weight polymers may form either solid films with an inhomogeneous roughness or solid polymer domains separated by the dry substrate. In technological applications, very dilute polymer solutions of high-molecular-weight polymers can be used to avoid inhomogeneities in solid films. These solutions form smooth solid films, and the film thickness can be controlled by the experimental coating conditions.

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

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.

Influence of Two Different Coating Application Methods on the Maintenance of the Nutritional Quality of Fresh-Cut Melon during Storage

This study aimed at evaluating the effects of two coating application methods, spraying and dipping, on the quality of fresh-cut melons. An alginate-based coating containing both ascorbic and citric acid was applied at two concentrations (5% and 10%) with both methods on fresh-cut melon. The nutritional quality of the products was investigated during 11 days of storage at 10 °C. The suitability and adaptability of the applied coatings on the fruit were evaluated based on rheological and microstructural properties. Moisture, carotenoids, total polyphenols and ascorbic acid content were analyzed on melon samples during storage. Results showed that the coating solution applied by the dipping method and at the highest concentration (10%), allowed to better maintain some quality characteristics of fresh-cut melon, thanks also to the better coating homogeneity and higher thickness observed through microstructural analysis.

Production and characterization of copper periodic open cellular structures made by 3D printing-replica technique

Additive manufacturing by 3D printing comprises a set of methods for production of 3D objects starting from a CAD file. Advantages of additive manufacturing combine high manufacturing resolution, a reduction of waste material, and the possibility of computer-aided design (CAD). When applied to the manufacturing of structured catalyst substrates, the latter enables the optimization of transport properties of the catalyst support. Despite several methods have been introduced for a variety of materials, copper, well known for its high thermal conductivity, is still difficult to be handled. In this work, a novel approach for the additive manufacturing of copper periodic open cellular structures (POCS) is proposed and investigated. It consists in the use of the replica manufacturing procedure starting from resin supports produced by 3D printing stereolithography. Micrometric high purity copper powder was effectively dispersed using a liquid medium based on organic components; the resulting slurry was used for the washcoat deposition on the resin supports. Structures with diamond unit cell shape (cell size of 2.5 mm and void fractions in the 0.8-0.9 range) were washcoated by dip-spin coating. Homogeneous washcoat layers were obtained without occurrence of cell clogging phenomena. Optimized thermal treatment procedure was assessed for sintering the copper POCS. The resulting matrices preserved the morphology of the original structure, reaching a resolution in the range of 70 to 120 μm. These materials can eventually be used as catalyst supports for heat-transfer limited applications (eg, steam reforming of methane), where copper-based substrates were demonstrated to be an effective solution for process intensification.

Recent advances and prospects of inkjet printing in heterogeneous catalysis

This review provides an insight into inkjet printing technology in the context of heterogeneous catalysis.