Recent Advances in 3D Printing of Structured Materials for Adsorption and Catalysis Applications

Mind the Gap: The Role of Mass Transfer in Shaped Nanoporous Adsorbents for Carbon Dioxide Capture

Adsorptive separations by nanoporous materials are major industrial processes. The industrial importance of solid adsorbents is only expected to grow due to the increased focus on carbon dioxide capture technology and energy-efficient separations. To evaluate the performance of an adsorbent and design a separation process, the adsorption thermodynamics and kinetics must be known. However, although diffusion kinetics determine the maximum production rate in any adsorption-based separation, this aspect has received less attention due to the challenges associated with conducting diffusion measurements. These challenges are exacerbated in the study of shaped adsorbents due to the presence of porosity at different length scales. As a result, adsorbent selection typically relies mainly on adsorption properties at equilibrium, i.e., uptake capacity, selectivity and adsorption enthalpy. In this Perspective, based on an extensive literature review on mass transfer of CO2 in nanoporous adsorbents, we discuss the importance and limitations of measuring diffusion in nanoporous materials, from the powder form to the adsorption bed, considering the nature of the process, i.e., equilibrium-based or kinetic-based separations. By highlighting the lack of and discrepancies between published diffusivity data in the context of CO2 capture, we discuss future challenges and opportunities in studying mass transfer across scales in adsorption-based separations.

Reactive Carbon Capture: Cooperative and Bifunctional Adsorbent-Catalyst Materials and Process Integration for a New Carbon Economy

ConspectusTo say the least, releasing CO2 into the atmosphere is reaping undue environmental consequences given the ever-present increase in severe global weather events over the past five years. However, it can be argued that-at least in the confines of current technological capabilities-the atmospheric release of CO2 is somewhat unavoidable given that even shifting toward clean energy sources-such as solar, nuclear, wind, battery, or H2 power-incurs an initial carbon requirement by way of manufacturing the very production abilities through which "clean" energy is generated. Even years from now, experts agree that energy production will be diversified and-as the global population continues to drive the growth of global energy consumption-thermal power derived from carbon combustion is likely to remain one intrinsic energetic source, of which CO2 will always be a byproduct. In this context, it is the responsibility of the scientific community to devise improved pathways of carbon management such that (i) the consequences of combustion on the global environment are reduced and (ii) carbon fuels can be leveraged in a sustainable fashion.In this Account, we discuss a pivotal perspective shift on CO2 emissions derived from a considerable breakthrough in material science from our work on shape engineering of nanoporous adsorbents and catalysts. This account details the development of materials which no longer vilify CO2 emissions as a valueless combustion byproduct, instead providing a path for them to become a potential feedstock. In more specific terms, this work details the development of structured, cooperative "bifunctional" materials (BFMs) comprised of (i) a high-temperature adsorbent and (ii) a heterogeneous catalyst that enable single-bed CO2 capture and utilization in oxidative ethane dehydrogenation (ODHE), oxidative propane dehydrogenation (ODHP), and dry methane reforming (DMR) processes. This Account begins with the conceptual development of the BFMs in the powdered state, followed by detailing the first-ever reports of structuring the materials into facile honeycomb contactors by 3D printing. The Account then summarizes the impressive performance of the 3D-printed BFMs, specifically focusing on how their catalysts (metal oxides and perovskites) influence their reactive CO2 capture performances in ODHE, ODHP, and DMR processes. Such promise of CO2-as-fuel offers a glimpse into the future of a diversified energy economy, in which CO2/fuel looping can play an important role. A major factor in achieving this future is, of course, developing an appropriately active catalyst; an account of whose first breakthroughs in material science are detailed herein.

Attaining Tailored Wicking Behavior with Additive Manufacturing

Additive manufacturing (AM) has opened a new pathway to create customized wicking materials. With lower manufacturing costs and a larger design space than many alternatives for wicking, AM is of particular value in fields such as thermal management and microfluidics. Fluid propagation during wicking in porous media, however, has largely remained limited to Washburnian (t ) behavior, and optimizing these materials for wicking in a variety of use cases presents a challenge. In this work, we present a method of tailoring wicking behavior to an arbitrary target function of propagation distance versus time, achieved through the use of AM to create nonuniform porous materials. Layers of parallel lines, each successive layer rotated 90° from the last, form a gridded structure with a spatially varying unit cell size for which analytical models for the capillary pressure and solid fraction and a semianalytical model for permeability were found. These models were validated with capillary rise experiments for spatially uniform porous materials over a range of solid fractions from 0.4 to 0.9. Leveraging these models and representing a nonuniform porous material as a series of Ohmic fluidic resistors, we created an inverse design algorithm that generates a wicking material with spatially varying parameters to achieve a specified target function for fluid propagation as a function of time. These materials can exhibit atypical wicking behavior, including fluid propagation displaying simple linear and piecewise linear relationships with time rather than the conventional Washburn relationship.

3D-Printed MOF Monoliths: Fabrication Strategies and Environmental Applications

Metal-organic frameworks (MOFs) have been extensively considered as one of the most promising types of porous and crystalline organic-inorganic materials, thanks to their large specific surface area, high porosity, tailorable structures and compositions, diverse functionalities, and well-controlled pore/size distribution. However, most developed MOFs are in powder forms, which still have some technical challenges, including abrasion, dustiness, low packing densities, clogging, mass/heat transfer limitation, environmental pollution, and mechanical instability during the packing process, that restrict their applicability in industrial applications. Therefore, in recent years, attention has focused on techniques to convert MOF powders into macroscopic materials like beads, membranes, monoliths, gel/sponges, and nanofibers to overcome these challenges.Three-dimensional (3D) printing technology has achieved much interest because it can produce many high-resolution macroscopic frameworks with complex shapes and geometries from digital models. Therefore, this review summarizes the combination of different 3D printing strategies with MOFs and MOF-based materials for fabricating 3D-printed MOF monoliths and their environmental applications, emphasizing water treatment and gas adsorption/separation applications. Herein, the various strategies for the fabrication of 3D-printed MOF monoliths, such as direct ink writing, seed-assisted in-situ growth, coordination replication from solid precursors, matrix incorporation, selective laser sintering, and digital light processing, are described with the relevant examples. Finally, future directions and challenges of 3D-printed MOF monoliths are also presented to better plan future trajectories in the shaping of MOF materials with improved control over the structure, composition, and textural properties of 3D-printed MOF monoliths.

Recent advances in environmental and agricultural applications of hydrochars: A review

Hydrochar is a carbonaceous material that is generated through the process of hydrothermal carbonization (HTC) from biomass, which has garnered considerable attention in recent years owing to its potential applications in a diverse range of fields, such as environmental remediation and agriculture. Hydrochar is produced from a diverse range of biomass waste materials and retains exceptional properties, including high carbon content, stability, and surface area, making it an optimal candidate for various enviro-agricultural applications. Moreover, it delves into the production process of hydrochar, with explicit emphasis on the optimization of certain properties during the production of hydrochar from bio-waste. Furthermore, the potential of hydrochar as an adsorbent and catalyst support for heavy metals and dyes was extensively explored, along with a soil remediation potential that can improve the physical, chemical and biological properties of soil. This comprehensive review aims to provide a thorough overview of hydrochar with a particular focus on its production, properties, and prospective applications. The significance of hydrochar is accentuated and the growing need for alternative sources of energy and materials that are environmentally sustainable is highlighted in this paper. Besides, the consequence of hydrochar on soil properties such as water-holding capacity, nutrient retention, and total soil porosity, as well as its influence on soil chemical properties such as cation exchange capacity, electrical conductivity, and surface functionality is scrutinized.

ZSM-5@ceramic foam composite catalyst derived from spent bleaching clay for continuous pyrolysis of waste oil to produce monocyclic aromatic hydrocarbons

Spent bleaching clay, a solid waste generated during the refining process of vegetable oils, lacks an efficient treatment solution. In this study, spent bleaching clay was innovatively employed to fabricate ceramic foams. The thermal stability analysis, microstructure, and crystal phase composition of the ceramic foams were characterized by TG-DSC, SEM, and XRD. An investigation into the influence of Al2O3 content on the ceramic foams was conducted. Results showed that, as the Al2O3 content increased from 15 wt% to 30 wt%, there was a noticeable decrease in bulk density and linear shrinkage, accompanied by an increase in compressive strength. Additionally, the ceramic foams were used as catalyst supports, to synthesize ZSM-5@ceramic foam composite catalysts for pyrolysis of waste oil. The open pores of the ZSCF catalyst not only reduced diffusion path length but also facilitated the exposure of more acid sites, thereby increasing the utilization efficiency of ZSM-5 zeolite. This, in turn, engendered a significant enhancement in monocyclic aromatic hydrocarbons content from 39.15 % (ZSM-5 powder catalyst) to 78.96 %. Besides, a larger support pore size and a thicker ZSM-5 zeolite coating layer led to an increase in monocyclic aromatic hydrocarbons content. As the time on stream was extended to 56 min, the monocyclic aromatic hydrocarbon content obtained with the composite catalyst remained 12.41 % higher than that of the ZSM-5 powder catalyst. These findings validate the potential of the composite catalyst. In essence, this study advances the utilization of spent bleaching clay and introduces a novel concept for ceramic foam fabrication. Furthermore, it contributes to the scaling up of catalytic pyrolysis technology.

Coaxial 3D Printing of Zeolite-Based Core-Shell Monolithic Cu-SSZ-13@SiO2 Catalysts for Diesel Exhaust Treatment

Core-shell catalysts with functional shells can increase the activity and stability of the catalysts in selective catalytic reduction of NOx with ammoniax. However, the conventional approaches based on multistep fabrication for core-shell structures encounter persistent restrictions regarding strict synthesis conditions and limited design flexibility. Herein, a facile coaxial 3D printing strategy is for the first time developed to construct zeolite-based core-shell monolithic catalysts with interconnected honeycomb structures, in which the hydrophilic noncompact silica serves as shell and Cu-SSZ-13 zeolite acts as core. Compared to a Cu-SSZ-13 monolith which suffers from the interfacial diffusion, the SiO2 shell layer can increase the accessibility of active sites over Cu-SSZ-13@SiO2, resulting in a 10-20% higher NO conversion at200-550 °C under 300 000 cm3 g-1 h-1. Meanwhile, a thicker SiO2 shell enhances the hydrothermal stability of the aged catalyst by inhibiting the dealumination and the formation of CuOx. Other representative monolithic catalysts with different topological zeolites as shell and diverse metal oxides as the core can be also realized by this coaxial 3D printing. This strategy allows multiple porous materials to be directly integrated, which allows for flexible design and fabrication of various core-shell monolithic catalysts with customized functionalities.

Zeolite/Polymer Composites Prepared by Photopolymerization: Effect of Compensation Cations on Opacity and Gas Adsorption Applications

The fabrication of structured zeolite adsorbents through photopolymerization-based 3D printing which offers a solution to the limitations of conventional shaping techniques has been demonstrated but many parameters still need to be optimized. In this study, we studied the influence of zeolite compensation cations on the photopolymerization and the composite's properties. Modified zeolites (LTA 4 A and FAU 13X exchanged with K+ , Li+ , Sr2+ , Ca2+ or Mg2+ ) were incorporated in PEGDA with BDMK as photoinitiator, and the formulation was cured under mild conditions (LED@405 nm, room temperature, under air). Our results indicate that the nature of zeolite compensation cations affects the colorimetric properties of polymer/zeolite composites: a better translucency parameter results in higher depth of cure. After calcination at 650 °C and complete removal of PEGDA, pure zeolitic monoliths were tested for adsorption of gas molecules of interest (carbon dioxide, dichlorobenzene and water). Structured 4 A and 13X monoliths obtained by 3D printing exhibit comparable adsorption capacity to commercial beads prepared from the same zeolites. This study enhances our understanding of the photopolymerization process involved in the production of polymer/zeolite composites. These composites are used in the fabrication of zeolitic objects through 3D printing, offering potential solutions to various environmental and dental challenges.

Reactive Capture and Conversion of CO2 into Hydrogen over Bifunctional Structured Ce1-xCoxNiO3/Ca Perovskite-Type Oxide Monoliths

Carbon capture, utilization, and storage (CCUS) technologies are pivotal for transitioning to a net-zero economy by 2050. In particular, conversion of captured CO2 to marketable chemicals and fuels appears to be a sustainable approach to not only curb greenhouse emissions but also transform wastes like CO2 into useful products through storage of renewable energy in chemical bonds. Bifunctional materials (BFMs) composed of adsorbents and catalysts have shown promise in reactive capture and conversion of CO2 at high temperatures. In this study, we extend the application of 3D printing technology to formulate a novel set of BFMs composed of CaO and Ce1-xCoxNiO3 perovskite-type oxide catalysts for the dual-purpose use of capturing CO2 and reforming CH4 for H2 production. Three honeycomb monoliths composed of equal amounts of adsorbent and catalyst constituents with varied Ce1-xCox ratios were 3D printed to assess the role of cobalt on catalytic properties and overall performance. The samples were vigorously characterized using X-ray diffraction (XRD), energy-dispersive spectroscopy (EDS), N2 physisorption, X-ray photoelectron spectroscopy (XPS), H2-TPR, in situ CO2 adsorption/desorption XRD, and NH3-TPD. Results showed that the Ce1-xCox ratios-x = 0.25, 0.50, and 0.75-did not affect crystallinity, texture, or metal dispersion. However, a higher cobalt content reduced reducibility, CO2 adsorption/desorption reversibility, and oxygen species availability. Assessing the structured BFM monoliths via combined CO2 capture and CH4 reforming in the temperature range 500-700 °C revealed that such differences in physiochemical properties lowered H2 and CO yields at higher cobalt loading, leading to best catalytic performance in Ce0.75Co0.25NiO3/Ca sample that achieved 77% CO2 conversion, 94% CH4 conversion, 61% H2 yield, and 2.30 H2/CO ratio at 700 °C. The stability of this BFM was assessed across five adsorption/reaction cycles, showing only marginal losses in the H2/CO yield. Thus, these findings successfully expand the use of 3D printing to unexplored perovskite-based BFMs and demonstrate an important proof-of-concept for their use in combined CO2 capture and utilization in H2 production processes.

Cold Temperature Direct Air CO2 Capture with Amine-Loaded Metal-Organic Framework Monoliths

Zeolites, silica-supported amines, and metal-organic frameworks (MOFs) have been demonstrated as promising adsorbents for direct air CO2 capture (DAC), but the shaping and structuring of these materials into sorbent modules for practical processes have been inadequately investigated compared to the extensive research on powder materials. Furthermore, there have been relatively few studies reporting the DAC performance of sorbent contactors under cold, subambient conditions (temperatures below 20 °C). In this work, we demonstrate the successful fabrication of adsorbent monoliths composed of cellulose acetate (CA) and adsorbent particles such as zeolite 13X and MOF MIL-101(Cr) by a 3D printing technique: solution-based additive manufacturing (SBAM). These monoliths feature interpenetrated macroporous polymeric frameworks in which microcrystals of zeolite 13X or MIL-101(Cr) are evenly distributed, highlighting the versatility of SBAM in fabricating monoliths containing sorbents with different particle sizes and density. Branched poly(ethylenimine) (PEI) is successfully loaded into the CA/MIL-101(Cr) monoliths to impart CO2 uptakes of 1.05 mmol gmonolith-1 at -20 °C and 400 ppm of CO2. Kinetic analysis shows that the CO2 sorption kinetics of PEI-loaded MIL-101(Cr) sorbents are not compromised in the monoliths compared to the powder sorbents. Importantly, these monoliths exhibit promising working capacities (0.95 mmol gmonolith-1) over 14 temperature swing cycles with a moderate regeneration temperature of 60 °C. Dynamic breakthrough experiments at 25 °C under dry conditions reveal a CO2 uptake capacity of 0.60 mmol gmonolith-1, which further increases to 1.05 and 1.43 mmol gmonolith-1 at -20 °C under dry and humid (70% relative humidity) conditions, respectively. Our work showcases the successful implementation of SBAM in making DAC sorbent monoliths with notable CO2 capture performance over a wide range of sorption temperatures, suggesting that SBAM can enable the preparation of efficient sorbent contactors in various form factors for other important chemical separations.

Three-Dimensional Printing of Cellulose/Covalent Organic Frameworks (CelloCOFs) for CO2 Adsorption and Water Treatment

The development of porous organic polymers, specifically covalent organic frameworks (COFs), has facilitated the advancement of numerous applications. Nevertheless, the limited availability of COFs solely in powder form imposes constraints on their potential applications. Furthermore, it is worth noting that COFs tend to undergo aggregation, leading to a decrease in the number of active sites available within the material. This work presents a comprehensive methodology for the transformation of a COF into three-dimensional (3D) scaffolds using the technique of 3D printing. As part of the 3D printing process, a composite material called CelloCOF was created by combining cellulose nanofibrils (CNF), sodium alginate, and COF materials (i.e., COF-1 and COF-2). The intervention successfully mitigated the agglomeration of the COF nanoparticles, resulting in the creation of abundant active sites that can be effectively utilized for adsorption purposes. The method of 3D printing can be described as a simple and basic procedure that can be adapted to accommodate hierarchical porous materials with distinct micro- and macropore regimes. This technology demonstrates versatility in its use across a range of COF materials. The adsorption capacities of 3D CelloCOF materials were evaluated for three different adsorbates: carbon dioxide (CO2), heavy metal ions, and perfluorooctanesulfonic acid (PFOS). The results showed that the materials exhibited adsorption capabilities of 19.9, 7.4-34, and 118.5-410.8 mg/g for CO2, PFOS, and heavy metals, respectively. The adsorption properties of the material were found to be outstanding, exhibiting a high degree of recyclability and exceptional selectivity. Based on our research findings, it is conceivable that the utilization of custom-designed composites based on COFs could present new opportunities in the realm of water and air purification.

Defect-Induced Secondary Crystals Drive Two-Dimensional to Three-Dimensional Morphological Evolution in the Co-Self-Assembly of Polyferrocenylsilane Block Copolymer and Homopolymer

Bottom-up fabrication protocols for uniform 3D hierarchical structures in solution are rare. We report two different approaches to fabricate uniform 3D spherulites and their precursors using mixtures of poly(ferrocenyldimethylsilane) (PFS) block copolymer (BCP) and PFS homopolymer (HP). Both protocols are designed to promote defects in 2D assemblies that serve as intermediate structures. In a multistep seeded growth protocol, we add the BCP/HP mixture to (1D) rod-like PFS micelles in a selective solvent as first-generation seeds. This leads to 2D platelet structures. If this step is conducted at a high supersaturation, secondary crystals form on the basal surface of these platelets. Co-crystallization and rapid crystallization of BCP/HP promote the formation of defects that act as nucleation sites for secondary crystals, resulting in multilayer platelets. This is the key step. The multilayer platelets serve as second-generation seeds upon subsequent addition of BCP/HP blends and, with increasing supersaturation, lead to the sequential formation of uniform (3D) hedrites, sheaves, and spherulites. Similar structures can also be obtained by a simple one-pot direct self-assembly (heating-cooling-aging) protocol of PFS BCP/HP blends. In this case, for a carefully chosen but narrow temperature range, PFS HPs nucleate formation of uniform structures, and the annealing temperature regulates the supersaturation level. In both protocols, the competitive crystallization kinetics of HP/BCP affects the morphology. Both protocols exhibit broad generality. We believe the morphological transformation from 2D to 3D structures, regulated by defect formation, co-crystallization, and supersaturation levels, could apply to various semicrystalline polymers. Moreover, the 3D structures are sufficiently robust to serve as recoverable carriers for nanoparticle catalysts, exhibiting valuable catalytic activity and opening new possibilities for applications requiring exquisite 3D structures.

Synthesis and Additive Manufacturing of Hydrazone-Linked Covalent Organic Framework Aerogels

Covalent Organic Frameworks (COFs) are crystalline, porous organic materials. Recent studies have demonstrated novel processing strategies for COFs to form adaptable architectures, but these have focused primarily on imine-linked COFs. This work presents a new synthesis and processing route to produce crystalline hydrazone-linked COF gels and aerogels with hierarchical porosity. The method was implemented to produce a series of hydrazone-linked COFs with different alkyl side-chain substituents, achieving control of the hydrophilicity of the final aerogel. Variation in the length of the alkyl substituents yielded materials with controllable form factors that can preferentially adsorb water or nonpolar organic solvents. Additionally, a method for additive manufacturing of hydrazone-linked COFs using hydroxymethylcellulose as a sacrificial additive is presented. This work demonstrates an effective and simple approach to the fabrication of hydrazone COF aerogels and additive manufacturing to produce hydrazone COFs of desired shape.

3D Printing Technique Fortifies the Ultradeep Hydrodesulfurization Process of Diesel: A Journey of NiMo/Al2O3-MMT

In this contribution, we rationally designed and controllably fabricated a NiMo/Al2O3-montmorillonite (3D-NiMo/Al2O3-MMT) monolithic catalyst via a 3D printing strategy with economical montmorillonite (MMT) as a binder. The catalytic performance of the resulting NiMo/Al2O3-MMT for 4,6-dimethyldibenzothiophene (4,6-DMDBT) hydrodesulfurization (HDS) was evaluated. The experimental results unveil that the 3D-NiMo/Al2O3-MMT monolithic catalyst exhibits robust stability and exceptional HDS activity with 99.2% 4,6-DMDBT conversion (residual 4 ppm of S), which is remarkably superior to that of conventional NiMo/Al2O3 (61.5%), NiMo/MMT (63.2%), and even NiMo/Al2O3-MMT (76.5%) prepared by the mechanical-mixing method. This should be ascribed to the synthetic effect between the MMT binder and the Al2O3 substrate, which effectively weakens the interaction between the Mo species and the Lewis acids on the original Al2O3 surface, thereby significantly increasing the content of reducible Mo species and considerably facilitating the formation of more highly active NiMoS phase (Type II) with optimal average stacking layers and thereafter remarkably enhancing the ultradeep HDS activity of the 3D-NiMo/Al2O3-MMT monolithic catalyst.

Application of three-dimensional printing technology in environmental analysis: A review

The development of environmental analysis devices with high performance is essential to assess the potential risks of environmental pollutants. However, it is still challenging to develop environmental analysis equipment with miniaturization, portability, and high sensitivity based on traditional processing techniques. In recent years, the popularity of 3D printing technology (3DP) with high precision, low cost, and unlimited design freedom has provided opportunities to solve the existing challenges of environmental analysis. 3D printing has brought solutions to promote the high performance and versatility of environmental analysis equipment by optimizing printing materials, enhancing equipment structure, and integrating multidisciplinary technology. In this paper, we comprehensively review the latest progress in 3D printing in various aspects of environmental analysis procedures, including but not limited to sample collection, pretreatment, separation, and detection. We highlight their advantages and challenges in determining various environmental contaminants through passive sampling, solid-phase extraction, chromatographic separation, and mass spectrometry detection. The manufacturing of 3D-printed environmental analysis devices is also discussed. Finally, we look forward to their development prospects and challenges.

Surface Chemical Engineering of a Metal 3D-Printed Flow Reactor Using a Metal-Organic Framework for Liquid-Phase Catalytic H2 Production from Hydrogen Storage Materials

The accurate positioning of metal-organic frameworks (MOFs) on the surface of other materials has opened up new possibilities for the development of multifunctional devices. We propose here a postfunctionalization approach for three-dimensional (3D)-printed metallic catalytic flow reactors based on MOFs. The Cu-based reactors were immersed into an acid solution containing an organic linker for the synthesis of MOFs, where Cu2+ ions dissolved in situ were assembled to form MOF crystals on the surface of the reactor. The resultant MOF layer served as a promising interface that enabled the deposition of catalytically active metal nanoparticles (NPs). It also acted as an efficient platform to provide carbonous layers via simple pyrolysis under inert gas conditions, which further enabled functionalization with organic modifiers and metal NPs. Cylindrical-shaped catalytic flow reactors with four different cell densities were used to investigate the effect of the structure of the reactors on the catalytic production of H2 from a liquid-phase hydrogen storage material. The activity increased with an increasing internal surface area but decreased in the reactor with the smallest cell size despite its high internal surface area. The results of fluid dynamics studies indicated that the effect of pressure loss becomes more pronounced as the pore size decreases.

Ionic Liquids Functionalized MOFs for Adsorption

Metal-organic frameworks (MOFs) and ionic liquids (ILs) represent promising materials for adsorption separation. ILs incorporated into MOF materials (denoted as IL/MOF composites) have been developed, and IL/MOF composites combine the advantages of MOFs and ILs to achieve enhanced performance in the adsorption-based separation of fluid mixtures. The designed different ILs are introduced into the various MOFs to tailor their functional properties, which affect the optimal adsorptive separation performance. In this Perspective, the rational fabrication of IL/MOF composites is presented, and their functional properties are demonstrated. This paper provides a critical overview of an emergent class of materials termed IL/MOF composites as well as the recent advances in the applications of IL/MOF composites as adsorbents or membranes in fluid separation. Furthermore, the applications of IL/MOF in adsorptive gas separations (CO2 capture from flue gas, natural gas purification, separation of acetylene and ethylene, indoor pollutants removal) and liquid separations (separation of bioactive components, organic-contaminant removal, adsorptive desulfurization, radionuclide removal) are discussed. Finally, the existing challenges of IL/MOF are highlighted, and an appropriate design strategy direction for the effective exploration of new IL/MOF adsorptive materials is proposed.

Recent Progress and Perspectives of Direct Ink Writing Applications for Mass Transfer Enhancement in Gas-Phase Adsorption and Catalysis

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.

3D printed solid phase microextraction scaffolds as novel tool for sample preparation; application in antifungal drugs analysis

3D printed solid phase microextraction scaffolds as a novel sorbent were introduced for the extraction of antifungal drugs in wastewater and human plasma prior to their determination by HPLC-UV. The designed adsorbent was prepared as cubic scaffolds using fused deposition modeling (FDM) 3D printer and Polylactic acid (PLA) filament. Scaffold surface was chemically modified using alkaline ammonia solution (Alkali treatment). The application of this new design in the extraction of three antifungal drugs ketoconazole, clotrimazole and miconazole was investigated. Alkali surface modification time was optimized (0.5-5hr) and 4hr selected as the best-modification time. Morphology of the modified surface and its chemical changes were studied using Field Emission Scanning Electron Microscope (FE-SEM) and Attenuated Total Reflectance Fourier Transform Infrared spectroscopy (ATR-FTIR), respectively. Surface wettability of scaffolds was measured by Water Contact Angel (WCA) and the porosity created in the scaffolds was studied by N₂ adsorption/desorption studies analysis. Analytical performance of the method, under optimum conditions (extraction time: 25 min, desorption solvent: methanol, volume of desorption solvent: 2 mL, desorption time: 10 min, solution pH: 8, solution temperature: 40 °C, salt concentration: 3 mol L^-1) were obtained as 3.10 and 10.0 µg L^-1 for LOD and LOQ, respectively. The calibration graphs were linear in the range of 10-150 µg L^-1 and 10-100 µg L^-1 for wastewater and plasma, respectively.

Low-concentration CO2 capture using metal-organic frameworks - current status and future perspectives

The ever-increasing atmospheric CO₂ level is considered to be the major cause of climate change. Although the move away from fossil fuel-based energy generation to sustainable energy sources would significantly reduce the release of CO₂ into the atmosphere, it will most probably take time to be fully implemented on a global scale. On the other hand, capturing CO₂ from emission sources or directly from the atmosphere are robust approaches that can reduce the atmospheric CO₂ concentration in a relatively short time. Here, we provide a perspective on the recent development of metal-organic framework (MOF)-based solid sorbents that have been investigated for application in CO₂ capture from low-concentration (<10 000 ppm) CO₂ sources. We summarized the different sorbent engineering approaches adopted by researchers, both from the sorbent development and processing viewpoints. We also discuss the immediate challenges of using MOF-based CO₂ sorbents for low-concentration CO₂ capture. MOF-based materials, with tuneable pore properties and tailorable surface chemistry, and ease of handling, certainly deserve continued development into low-cost, efficient CO₂ sorbents for low-concentration CO₂ capture.

A robust and 3D-printed solar evaporator based on naturally occurring molecules

The interfacial solar desalination has been considered a promising method to address the worldwide water crisis without sophisticated infrastructures and additional energy consumption. Although various advanced solar evaporators have been developed, their practical applications are still restricted by the unsustainable materials and the difficulty of precise customization for structure to escort high solar-thermal efficiency. To address these issues, we employed two kinds of naturally occurring molecules, tannic acid and iron (III), to construct a low-cost, highly efficient and durable interfacial solar evaporator by three-dimensional (3D) printing. Based on a rational structural design, a robust and 3D-printed evaporator with conical array surface structure was developed, which could promote the light harvesting capacity significantly via the multiple reflections and anti-reflection effects on the surface. By optimizing the height of the conical arrays, the 3D-printed evaporator with tall-cone structure could achieve a high evaporation rate of 1.96 kg m^-2 h^-1 under one sun illumination, with a photothermal conversion efficiency of 94.4%. Moreover, this evaporator was also proved to possess excellent desalination performance, recycle stability, anti-salt property, underwater oil resistance, as well as adsorption capacity of organic dye contaminants for multipurpose water purification applications. It was believed that this study could provide a new strategy to fabricate low-cost, structural regulated solar evaporators for alleviating the dilemma of global water scarcity using abundant naturally occurring building blocks.

Colloidal Stabilization of Submicron-Sized Zeolite NaA in Ethanol-Water Mixtures for Nanostructuring into Thin Films and Nanofibers

Despite the growing use of organic or mixed solvents in zeolite processing, most studies focus only on aqueous suspension systems. We investigated the colloidal characteristics of submicron-sized zeolite NaA in mixed ethanol-water solvents. The effects of the mixing ratio of solvents and various additives on the dispersion of the zeolite powders were studied. The zeolite NaA particles were destabilized in solvent mixtures at a high ethanol-to-water ratio, a reduction in the zeta potential was observed, and the destabilization was rationalized by the Derjaguin, Landau, Verwey, Overbeek (DLVO) theory. An improved stabilization of the zeolite NaA suspensions was achieved in ethanol-rich solvent mixtures using nonionic low molecular weight organic additives, but not with their ionic counterparts such as anionic, cationic surfactants or inorganic acids or bases. Polyethylene glycol (PEG)-400 was found to be a good dispersant for the submicron-sized zeolite NaA particles in the ethanol-water mixtures, which was attributed to its interaction with the zeolite surface, leading to an increased zeta potential. The PEG-stabilized zeolite suspensions led to low suspension viscosities as well as uniform and consistent spin-coated films.

Blood-Coagulation-Inspired Dynamic Bridging Strategy for the Fabrication of Multiscale-Assembled Hierarchical Porous Material

Porous materials, from macroscopic bulk materials (MBs) with (sub-)millimeter-scale pores to tiny particles (TPs) with (sub-)nanometer-scale pores, have attracted ever-growing interest in various fields. However, the integration of multi-scale pores in one composite is promising but challenging, owing to the considerable gap in the scale of the pores. Inspired by blood coagulation, a fibrin-based dynamic bridging strategy is developed to fabricate a multiscale-assembled hierarchical porous material (MHPM), in which fibrin formed as the sub-framework for the weaving-narrow of MBs and the enwinding-load of TPs. The bio-polymerization nature makes the fabrication rapid, facile, and universal for the customizable integration of seven kinds of TPs and four kinds of MBs. Besides, the integration is controllable with high load capacity of TPs and is stable against external shock forces. The unique multi-level structure endows the MHPM with large and accessible surface area, and efficient mass transfer pathways, synergistically leading to high adsorption capacity and rapid kinetics in multiple adsorption models. This work suggests a strategy for the rational multi-level design and fabrication of hierarchical porous architectures.

MXene-Based Porous Monoliths

In the past decade, a thriving family of 2D nanomaterials, transition-metal carbides/nitrides (MXenes), have garnered tremendous interest due to its intriguing physical/chemical properties, structural features, and versatile functionality. Integrating these 2D nanosheets into 3D monoliths offers an exciting and powerful platform for translating their fundamental advantages into practical applications. Introducing internal pores, such as isotropic pores and aligned channels, within the monoliths can not only address the restacking of MXenes, but also afford a series of novel and, in some cases, unique structural merits to advance the utility of the MXene-based materials. Here, a brief overview of the development of MXene-based porous monoliths, in terms of the types of microstructures, is provided, focusing on the pore design and how the porous microstructure affects the application performance.

Development of Power-to-X Catalytic Processes for CO2 Valorisation: From the Molecular Level to the Reactor Architecture

Nowadays, global climate change is likely the most compelling problem mankind is facing. In this scenario, decarbonisation of the chemical industry is one of the global challenges that the scientific community needs to address in the immediate future. Catalysis and catalytic processes are called to play a decisive role in the transition to a more sustainable and low-carbon future. This critical review analyses the unique advantages of structured reactors (isothermicity, a wide range of residence times availability, complex geometries) with the multifunctional design of efficient catalysts to synthesise chemicals using CO2 and renewable H2 in a Power-to-X (PTX) strategy. Fine-chemistry synthetic methods and advanced in situ/operando techniques are essential to elucidate the changes of the catalysts during the studied reaction, thus gathering fundamental information about the active species and reaction mechanisms. Such information becomes crucial to refine the catalyst’s formulation and boost the reaction’s performance. On the other hand, reactors architecture allows flow pattern and temperature control, the management of strong thermal effects and the incorporation of specifically designed materials as catalytically active phases are expected to significantly contribute to the advance in the valorisation of CO2 in the form of high added-value products. From a general perspective, this paper aims to update the state of the art in Carbon Capture and Utilisation (CCU) and PTX concepts with emphasis on processes involving the transformation of CO2 into targeted fuels and platform chemicals, combining innovation from the point of view of both structured reactor design and multifunctional catalysts development.

Synthesis and shaping of metal-organic frameworks: a review

Metal-organic frameworks (MOFs) possess excellent advantages, such as high porosity, large specific surface area, and an adjustable structure, showing good potential for applications in gas adsorption and separation, catalysis, conductivity, sensing, magnetism, etc. However, they still suffer from significant limitations in terms of the scale-up synthesis and shaping, hindering the realization of large-scale commercial applications. Despite some attempts having been devoted to addressing this, challenges remain. In this paper, we outline the advantages and drawbacks of existing synthetic routes such as electrochemistry, microwave, ultrasonic radiation, green solvent reflux, room temperature stirring, steam-assisted transformation, mechanochemistry, and fluid chemistry in terms of scale-up production. Then, the shaping methods of MOFs such as extrusion, mechanical compaction, rolling granulation, spray drying, gel technology, embedded granulation, phase inversion, 3D printing and other shaping methods for the preparation of membranes, coatings and nanoparticles are discussed. Finally, perspectives on the large-scale synthesis and shaping of MOFs are also proposed. This work helps provide in-depth insight into the scale-up production and shaping process of MOFs and boost commercial applications of MOFs.

Direct Ink 3D Printing of Porous Carbon Monoliths for Gas Separations

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.

3D Printing Flexible Sodium-Ion Microbatteries with Ultrahigh Areal Capacity and Robust Rate Capability

Rechargeable sodium-ion microbatteries (NIMBs) constructed using low-cost and abundant raw materials in planar configuration with both cathode and anode on the same substrate hold promise for powering coplanar microelectronics, but are hindered by the low areal capacity owing to the thin microelectrodes. Here, a prototype of planar and flexible 3D-printed NIMBs is demonstrated with 3D interconnected conductive thick microelectrodes for ultrahigh areal capacity and boosted rate capability. Rationally optimized 3D printable inks with appropriate viscosities and high conductivity allow the multilayer printing of NIMB microelectrodes reaching a very high thickness of ≈1200 µm while maintaining effective ion and electron-transfer pathways in them. Consequently, the 3D-printed NIMBs deliver superior areal capacity of 4.5 mAh cm^-2 (2 mA cm^-2 ), outperforming the state-of-the-art printed microbatteries. The NIMBs show enhanced rate capability with 3.6 mAh cm^-2 at 40 mA cm^-2 and robust long-term cycle life up to 6000 cycles. Furthermore, the planar NIMB microelectrodes, despite the large thickness, exhibit decent mechanical flexibility under various bending conditions. This work opens a new avenue for the construction of high-performance NIMBs with thick microelectrodes capable of powering flexible microelectronics.

MOF/POM hybrids as catalysts for organic transformations

Insertion of molecular metal oxides, e.g. polyoxometalates (POMs), into metal-organic frameworks (MOFs) opens up new research opportunities in various fields, particularly in catalysis. POM/MOF composites have strong acidity, oxygen-rich surface, and redox capacity due to typical characteristics of POMs and the large surface area, highly organized structures, tunable pore size, and shape are due to MOFs. Such hybrid materials have gained a lot of attention due to astonishing structural features, and hence have potential applications in organic catalysis, sorption and separation, proton conduction, magnetism, lithium-ion batteries, supercapacitors, electrochemistry, medicine, bio-fuel, and so on. The exceptional chemical and physical characteristics of POMOFs make them useful as catalysts in simple organic transformations with high capacity and selectivity. Here, the thorough catalytic study starts with a brief introduction related to POMs and MOFs, and is followed by the synthetic strategies and applications of these materials in several catalytic organic transformations. Furthermore, catalytic conversions like oxidation, condensation, esterification, and some other types of catalytic reactions including photocatalytic reactions are discussed in length with their plausible catalytic mechanisms. The disadvantages of the POMOFs and difficulties faced in the field have also been explored briefly from our perspectives.

3D-printed heterogeneous Cu2O monoliths: Reusable supports for Antibiotic Treatmentantibiotic treatment of wastewater

In this study, surfactant stabilized dispersions of the Cu₂O microparticles in a commercially available photocurable resin were 3D printed into both porous and non-porous monoliths, and the heterogeneous Cu₂O catalytic monolith with improved mass transfer characteristics was applied for antibiotic wastewater treatment. The physicochemical properties of catalytic monoliths were characterized by scanning electron microscopy, X-ray diffraction, X-ray photoelectron spectroscopy and thermogravimetric. Ten intermediates were analyzed and identified by GC-MS, and the corresponding degradation pathways were proposed. Both numerical simulation and degradation experiments were used to explore the mass transfer mechanism and catalytic performance of the monoliths. The results showed that the 3D-printed monolith with a well-defined porous network exhibited a high ofloxacin degradation efficiency (100%) based on the sulfate radical-based advanced oxidation processes. In addition, the catalytic monolith showed sustained high activity over 7 reusable cycles demonstrating its feasibility in removal of antibiotics from wastewater.

Recent advances in direct air capture by adsorption

Significant progress has been made in direct air capture (DAC) in recent years. Evidence suggests that the large-scale deployment of DAC by adsorption would be technically feasible for gigatons of CO₂ capture annually. However, great efforts in adsorption-based DAC technologies are still required. This review provides an exhaustive description of materials development, adsorbent shaping, in situ characterization, adsorption mechanism simulation, process design, system integration, and techno-economic analysis of adsorption-based DAC over the past five years; and in terms of adsorbent development, affordable DAC adsorbents such as amine-containing porous materials with large CO₂ adsorption capacities, fast kinetics, high selectivity, and long-term stability under ultra-low CO₂ concentration and humid conditions. It is also critically important to develop efficient DAC adsorptive processes. Research and development in structured adsorbents that operate at low-temperature with excellent CO₂ adsorption capacities and kinetics, novel gas-solid contactors with low heat and mass transfer resistances, and energy-efficient regeneration methods using heat, vacuum, and steam purge is needed to commercialize adsorption-based DAC. The synergy between DAC and carbon capture technologies for point sources can help in mitigating climate change effects in the long-term. Further investigations into DAC applications in the aviation, agriculture, energy, and chemical industries are required as well. This work benefits researchers concerned about global energy and environmental issues, and delivers perspective views for further deployment of negative-emission technologies.

Multifunctional Hydroxyapatite Composites for Orthopedic Applications: A Review

Being a bioactive material, hydroxyapatite (HAp) is regarded as one of the most attractive ceramic biomaterials for bone and hard-tissue replacement and regeneration. Despite its substantial biocompatibility, osteoconductivity, and compositional similarity to that of bone, the employment of HAp is still limited in orthopedic applications due to its poor mechanical (low fracture toughness and bending strength) and antibacterial properties. These significant challenges lead to the notion of developing novel HAp-based composites via different fabrication routes. HAp, when efficaciously combined with functionally graded materials and antibacterial agents, like Ag, ZnO, Co, etc., form composites that render remarkable crack resistance and toughening, as well as enhance its bactericidal efficacy. The addition of different materials and a fabrication method, like 3D printing, greatly influence the porosity of the structure and, in turn, control cell adhesion, thereby enabling biological fixation of the material. This article encompasses an elaborate discussion on different multifunctional HAp composites developed for orthopedic applications with particular emphasis on the incorporation of functionally graded materials and antibacterial agents. The influence of 3D printing on the fabrication of HAp-based scaffolds, and the different in vitro and in vivo studies conducted on these, have all been included here. Furthermore, the present review not only provides insights and broad understanding by elucidating recent advancements toward 4D printing but also directs the reader to future research directions in design and application of HAp-based composite coatings and scaffolds.

Recent Advances in Carbon-Based Adsorbents for Adsorptive Separation of Light Hydrocarbons

Light hydrocarbons (LHs) separation is an important process in petrochemical industry. The current separation technology predominantly relies on cryogenic distillation, which results in considerable energy consumption. Adsorptive separation using porous solids has received widespread attention due to its lower energy footprint and higher efficiency. Thus, tremendous efforts have been devoted to the design and synthesis of high-performance porous solids. Among them, porous carbons display exceptional stability, tunable pore structure, and surface chemistry and thus represent a class of novel adsorbents upon achieving the matched pore structures for LHs separations. In this review, the modulation strategies toward advanced carbon-based adsorbents for LHs separation are firstly reviewed. Then, the relationships between separation performances and key structural parameters of carbon adsorbents are discussed by exemplifying specific separation cases. The research findings on the control of the pore structures as well as the quantification of the adsorption sites are highlighted. Finally, the challenges of carbonaceous adsorbents facing for LHs separation are given, which would motivate us to rationally design more efficient absorbents and separation processes in future.

Adsorption film with sub-milli-interface morphologies via direct ink writing for indoor formaldehyde removal

In-situ thermally regenerated flexible adsorption films are superior for long-term purification of indoor low-concentration volatile organic compounds (VOCs). To further improve the adsorption kinetics of the films, the surface morphology of adsorption films was suggested in hierarchical channel structure. However, such structure is far from practical applications because of its complicated fabrication method and limited flexibility. In this study, we proposed a convenient and fast method named direct ink writing (DIW) based 3D printing to fabricate flexible adsorption films. Inks were prepared to have appropriate rheological properties and good printability. Three types of adsorption film (flat, straight finned, and trough-like finned) were constructed on flexible polyimide circuit substrates by DIW. We utilized the printed adsorption films for indoor level (1 ppm) formaldehyde removal. The trough-like finned film achieved the best performance among the three printed films, showing a 275% longer penetration time and 252% larger effective adsorption capacity than the flat film. By conducting a 7-cycle adsorption-desorption experiment (more than 12 h), we verified that the films' adsorption performance could effectively recover via in-situ heating. This work could dance around the complicated coating process, increase the structural flexibility and reduce the adsorbent interfacial modification cost.

3D printing of TiO2 nano particles containing macrostructures for As(III) removal in water

Nanomaterials play a crucial role in various areas due to their extraordinary chemical and physical properties. Loading microscopic nanomaterials onto macrostructures is inevitable for their implementation from laboratory experiments to practical applications. Nevertheless, the geometries of conventional supporting structures are usually limited and nanomaterials are easy to be inhomogeneously distributed, aggregated, and lost. Therefore, controllably configuring nanomaterials into sophisticated three-dimensional macroscopic structures without sacrificing their inherent properties remains challenging. Here we utilize the advantages of 3D printing technology to realize this purpose. As a proof-of-concept, the application of 3D stereolithography printed macrostructures containing TiO₂ nano particles (TiO₂ NPs) for direct adsorption removal of As(III) in water was demonstrated. The morphology and distribution of TiO₂ NPs mounted on printed macrostructures were initially characterized. Then batch adsorption experiments were conducted to investigate the effect of the 3D printing process, TiO₂ NPs doped concentration and TiO₂ NP size as well as adsorption kinetics and isotherms. We also demonstrated that 3D printed adsorption structures could be easily reused over 10 times and were effective for raw arsenic-polluted groundwater samples. Our findings show that 3D printing provides a promising route to design and fabricate customized macrostructures endowed with specific properties of nanomaterials.

Enhancement of wastewater treatment performance using 3D printed structures: A major focus on material composition, performance, challenges, and sustainable assessment

In order to enhance the performance and sustainability of wastewater treatment technologies, researchers are showing keen interest in the development of novel materials which can overcome the drawbacks associated with conventional materials. In this context, 3D printing gained significant attention due to its capability of fabricating complex geometrics using different material compositions. The present review focuses on recent advancements of 3D printing applications in various physicochemical and biological wastewater treatment techniques. In physicochemical treatment methods, substantial research has been aimed at fabricating feed spacers and other membrane parts, photocatalytic feed spacers, catalysts, scaffolds, monoliths, and capsules. Several advantages, such as membrane fouling mitigation, enhanced degradation efficiency, and recovery and reusability potential, have been associated with the aforementioned 3D printed materials. While in biofilm-based biological treatment methods, the use of 3D printed bio-carriers has led to enhanced mass transfer efficiency and microbial activities. Moreover, the application of these bio-carriers has shown better removal efficiency of chemical oxygen demand (∼90%), total nitrogen (∼73%), ammonia nitrogen (95%), and total phosphorous (∼100%). Although the removal efficiencies were comparable with conventional carriers, 3D printed carriers led to ∼40% reduction in hydraulic retention time, which could significantly save capital and operational expenditures. This review also emphasizes the challenges and sustainability aspects of 3D printing technology and outlines future recommendations which could be vital for further research in this field.

Phosphor-Enhanced, Visible-Light-Storing g-C3N4/Ag3PO4/SrAl2O4:Eu2+,Dy3+ Photocatalyst Immobilized on Fractal 3D-Printed Supports

The combination of a phosphor with semiconductor photocatalysts can provide photoactivity in the dark. Indeed, the phosphor acts as a "light battery", harvesting photons during irradiation and later re-emitting light that can be used by the catalytic phase when in conditions of total darkness. This allows for continued activity of the composite catalyst, even in conditions of unstable light stimulation. In this study, we assess the use of a heterojunction, namely graphitic-C₃N₄/Ag₃PO₄, that enables efficient photoactivity specifically under visible light stimulation, in combination with a phosphor that exhibits green-blue phosphorescence (510 nm), that is SrAl₂O₄:Eu²⁺,Dy³⁺. Our findings showed that this combination was particularly interesting, noticeably displaying significant photoactivity in darkness, after short periods of activation by visible light. After finding the right combination and optimal ratios for maximum efficiency, the resulting catalyst composite was immobilized on resin supports with a fractal surface, printed by LCD-SLA 3D printing. The immobilization was effectuated via an aqueous-phase plasma-aided grafting (APPAG) process, using cold plasma discharge (CPD) and using vinylphosphonic acid (VPA) as a coupling agent. Whereas the colloidal photocatalyst displayed a serious problem of partial physical separation between the catalytic phase, g-C₃N₄/Ag₃PO₄, and the phosphor, the immobilization of the composite catalyst on polymer supports allowed solving this issue. Photodegradation assessments confirmed that the hybrid supported phosphor-enhanced catalyst was active, notably in dark conditions, as well as fairly photostable. This study offers new prospects for the fabrication of polymer-based panels for water purification, with round-the-clock activity and that are, in addition, extremely easy to recover and reuse, by comparison with colloidal catalysts.

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

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.

Polymer–Nickel Composite Filaments for 3D Printing of Open Porous Materials

Catalysis has been a key way of improving the efficiency-to-cost ratio of chemical and electrochemical processes. There have been recent developments in catalyst materials that enable the development of novel and more sophisticated devices that, for example, can be used in applications, such as membranes, batteries or fuel cells. Since catalytic reactions occur on the surface, most catalyst materials are based on open porous structures, which facilitates the transport of fluids (gas or liquid) and chemical (or electrochemical) specific surface activity, thus determining the overall efficiency of the device. Noble metals are typically used for low temperature catalysis, whereas lower cost materials, such as nickel, are used for catalysis at elevated temperatures. 3D printing has the potential to produce a more sophisticated fit for purpose catalyst material. This article presents the development, fabrication and performance comparison of three thermoplastic composites where PLA (polylactic acid), PVB (polyvinyl butyral) or ABS (acrylonitrile butadiene styrene) were used as the matrix, and nickel particles were used as filler with various volume fractions, from 5 to 25 vol%. The polymer–metal composites were extruded in the form of filaments and then used for 3D FDM (Fused Deposition Modeling) printing. The 3D printed composites were heat treated to remove the polymer and sinter the nickel particles. 3D printed composites were also prepared using nickel foam as a substrate to increase the final porosity and mechanical strength of the material. The result of the study demonstrates the ability of the optimized filament materials to be used in the fabrication of high open porosity (over 60%) structures that could be used in high-temperature catalysis and/or electrocatalysis.

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

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.

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.

3D-Printed Fe/γ-Al2O3 Monoliths from MOF-Based Boehmite Inks for the Catalytic Hydroxylation of Phenol

The synthesis of dihydroxybenzenes (DHBZ), essential chemical reagents in numerous industrial processes, with a high degree of selectivity and yield from the hydroxylation of phenol is progressively attracting great interest in the catalysis field. Furthermore, the additive manufacturing of catalysts to produce 3D printed monoliths would provide additional benefits to enhance the DHBZ synthesis performance. Herein, 3D cellular Fe/γ-Al₂O₃ monoliths with a total porosity of 88% and low density (0.43 g·cm^-3) are printed by Robocasting from pseudoplastic Fe-metal-organic frameworks (Fe-MOF)-based aqueous boehmite inks to develop catalytic monoliths containing a Fe network of dispersed clusters (≤5 μm), nanoclusters (<50 nm), and nanoparticles (∼20 nm) into the porous ceramic skeleton. The hydroxylation of phenol in the presence of hydrogen peroxide is carried out at different reaction temperatures (65-85 °C) in a flow reactor filled with eight stacked 3D Fe/γ-Al₂O₃ monoliths and with the following operating conditions: C_phenol,0 = 0.33 M, C_phenol,0/C_H2O2,0 = 1:1 molar, W_R = 2.2 g, and space time (τ = W·Q_L^-1) = 0-147 g_cat·h·L^-1. The scaffolds present a good mechanical resistance (∼1 MPa) to be employed in a catalytic reactor and do not show any cracks or damage after the chemical reaction. DHBZ selectivity (S_DHBZ) of 100% with a yield (Y_DHBZ) of 32% due to the presence of the Fe network in the monoliths is reported at 85 °C, which represents an improved synthesis performance as compared to that obtained by using the conventional Enichem process and the well-known titanium silicalite-1 catalysts (S_DHBZ = 99.1% and Y_DHBZ = 29.6% at 80 °C). This printing strategy allows manufacturing novel 3D structured catalysts for the synthesis of critical chemical compounds with higher reaction efficiencies.