Three-Dimensional Hierarchical Porous Structures of Metallic Glass/Copper Composite Catalysts by 3D Printing for Efficient Wastewater Treatments

Wood-inspired metamaterial catalyst for robust and high-throughput water purification

Continuous industrialization and other human activities have led to severe water quality deterioration by harmful pollutants. Achieving robust and high-throughput water purification is challenging due to the coupling between mechanical strength, mass transportation and catalytic efficiency. Here, a structure-function integrated system is developed by Douglas fir wood-inspired metamaterial catalysts featuring overlapping microlattices with bimodal pores to decouple the mechanical, transport and catalytic performances. The metamaterial catalyst is prepared by metal 3D printing (316 L stainless steel, mainly Fe) and electrochemically decorated with Co to further boost catalytic functionality. Combining the flexibility of 3D printing and theoretical simulation, the metamaterial catalyst demonstrates a wide range of mechanical-transport-catalysis capabilities while a 70% overlap rate has 3X more strength and surface area per unit volume, and 4X normalized reaction kinetics than those of traditional microlattices. This work demonstrates the rational and harmonious integration of structural and functional design in robust and high throughput water purification, and can inspire the development of various flow catalysts, flow batteries, and functional 3D-printed materials.

Functionalisation of alkali-resistant nanoporous glass via Au nanoparticle decoration using alkaline impregnation: catalytic activity for CO removal

The concerted use of nano-metal particles with catalytic functions and nanoporous materials holds promise for effective air purification and gas sensing; however, only a few studies have used porous glasses as supports for Au nanoparticles. Furthermore, Au/nanoporous glasses with activities comparable to that of Au/TiO2, which is a typical Au catalyst, have not been reported to date. This study demonstrates that a nanoporous glass, which is highly acid- and alkali-resistant and chemically stable, can be decorated with Au nanoparticles using an alkali impregnation method. The resulting composite exhibits high catalytic activity in CO oxidation. The catalysts reported herein are as active as Au/TiO2 catalysts per active site. Further optimisation of the pore properties of the glass and sizes of the Au nanoparticles is expected to result in excellent catalytic systems for CO removal and sensing.

3D-printed MoS2/Ni electrodes with excellent electro-catalytic performance and long-term stability for dechlorination of florfenicol

Here, we report the production of 3D-printed MoS2/Ni electrodes (3D-MoS2/Ni) with long-term stability and excellent performance by the selective laser melting (SLM) technique. As a cathode, the obtained 3D-MoS2/Ni could maintain a degradation rate above 94.0% for florfenicol (FLO) when repeatedly used 50 times in water. We also found that the removal rate of FLO by 3D-MoS2/Ni was about 12 times higher than that of 3D-printed pure Ni (3D-Ni), attributed to the improved accessibility of H*. In addition, the electrochemical characterization results showed that the electrochemically active surface area of the 3D-MoS2/Ni electrode is about 3-fold higher than that of the 3D-Ni electrode while the electrical resistance is 4 times lower. Based on tert-butanol suppression, electron paramagnetic resonance and triple quadrupole mass spectrometer experiments, a "dual path" mechanism and possible degradation pathway for the dechlorination of FLO by 3D-MoS2/Ni were proposed. Furthermore, we also investigated the impacts of the cathode potential and the initial pH of the solution on the degradation of FLO. Overall, this study reveals that the SLM 3D printing technique is a promising approach for the rapid fabrication of high-stability metal electrodes, which could have broad application in the control of water contaminants in the environmental field.

Development of MoS2-stainless steel catalyst by 3D printing for efficient destruction of organics via peroxymonosulfate activation

Herein, a novel MoS2-stainless steel composite material was first synthetized via a 3D printing method (3DP MoS2-SS) for peroxymonosulfate (PMS) activation and organics degradation. Compared with MoS2-SS powder/PMS system (0.37 g/(m2/min)), 4.3-fold higher kFLO/SBET value was obtained in 3DP MoS2-SS/PMS system (1.60 g/(m2/min), resulting from the superior utilization of active sites. We observed that 3DP MoS2-SS significantly outperformed the 3DP SS due to the enhanced electron transfer rate and increased active sites. Moreover, Mo4+ facilitated the Fe2+/Fe3+ cycle, resulting in the rapid degradation of florfenicol (FLO). Quenching experiments and electron paramagnetic resonance spectra indicated that •OH, SO4•-, O2•- and 1O2 were involved in the degradation of FLO. The effect of influencing factors on the degradation of FLO were evaluated, and the optimized degradation efficiency of 98.69% was achieved at 1 mM PMS and pH of 3.0. Six degradation products were detected by UPLC/MS analyses and several possible degradation pathways were proposed to be the cleavage of C-N bonds, dechlorination, hydrolysis, defluorination and hydroxylation. In addition, 3DP MoS2-SS/PMS system also demonstrated superior degradation performance for 2-chlorophenol, acetaminophen, ibuprofen and carbamazepine. This study provided deep insights into the MoS2-SS catalyst prepared by 3DP technology for PMS activation and FLO-polluted water treatment.

Removal of nitrate by FeSiBC metallic glasses: high efficiency and superior reusability

The development of sustainable technologies for efficient nitrate removal has attracted increasing attention, because excessive nitrate emissions can result in serious environmental, economic, and health effects. Herein, we propose to utilize FeSiBC metallic glass (MG) powders as a potential solution for nitrate removal. In terms of removal efficiency and reusability, our results show that the MG powders, as special zero-valent iron carriers, are 2-3 orders of magnitude more efficient in nitrate removal than the previous studies, while maintaining more than 50% nitrate removal efficiency after 9 cycles of reaction. Moreover, the optimal FeSiBC MG dosage, pH value, and temperature for nitrate removal are determined. The mechanism of nitrate removal is also revealed. The present study offers a promising approach to remediate nitrate, one of the world's most widespread water pollutants.

Rapid fabrication of nanoporous iron by atmospheric plasma for efficient wastewater treatment

Nanoporous (NP) iron with large surface area is highly desired for wastewater degradation catalysis. However, it remains a challenge for the fabrication of NP-Fe because the conventional aqueous dealloying or liquid metal dealloying are not applicable. Herein, a novel and universal plasma-assisted electro-dealloying technique was utilized to fabricate NP-Fe. The NP-Fe demonstrates evenly distributed pore structure. The pore density can be tuned by the variation of the ratio of Fe and Zn in the precursor, and the average pore size can be tuned by the processing time. Owing to its large specific surface area, the NP-Fe shows excellent wastewater degradation performance, which is 26 times better than that of commercial zero-valent iron catalysts. This study provides a useful approach to fabricate NP active metals with enhanced catalytic performance.

The Role of 3D Printing in the Development of a Catalytic System for the Heterogeneous Fenton Process

Recycling of catalysts is often performed. Additive manufacturing (AM) received increasing attention in recent years in various fields such as engineering and medicine, among others. More recently, the fabrication of three-dimensional objects used as scaffolds in heterogeneous catalysis has shown innumerable advantages, such as easier handling and waste reduction, both leading to a reduction in times and costs. In this work, the fabrication and use of 3D-printed recyclable polylactic acid (PLA) scaffolds coated with an iron oxide active catalyst for Fenton reactions applied to aromatic model molecules, is presented. These molecules are representative of a wider class of intractable organic compounds, often present in industrial wastewater. The 3D-printed PLA-coated scaffolds were also tested using an industrial wastewater, determining the chemical oxygen demand (COD). The catalyst is characterized using electron microscopy coupled to elemental analysis (SEM/EDX) and thermogravimetry, demonstrating that coating leach is very limited, and it can be easily recovered and reused many times.

Catalytic Materials by 3D Printing: A Mini Review

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.

Rational Design and Construction of Monolithic Ordered Mesoporous Co3O4@SiO2 Catalyst by a Novel 3D Printed Technology for Catalytic Oxidation of Toluene

Here, we report a novel 3D printed layered ordered mesoporous template that can encapsulate active Co-MOFs species in a confined way to achieve the goal of monolithic catalyst. The monolithic OM-Co₃O₄@SiO₂-S catalyst can maintain a macroscopic porous layered structure and a microscopic ordered mesoporous structure. This monolithic OM-Co₃O₄@SiO₂-S catalyst has excellent catalytic performance (T₉₀ = 236 °C), water resistance, and thermal stability in the catalytic combustion of toluene. The catalytic performance of the monolithic OM-Co₃O₄@SiO₂-S catalyst is much better than that of many monolithic catalysts reported in the former. Among them, the introduction of binder aluminum phosphate (AP) can effectively enhance the rheological properties of the printing ink, achieve the purpose of ink writing monolithic layered porous material, enrich the acidic point of the monolithic catalyst, and increase the number of reactive oxygen species. This work reveals a novel monolithic catalyst forming strategy that can combine the advantages of ordered mesoporous materials with active species to form macro-layered porous materials and provide ideas and an experimental basis for the elimination of VOCs in industrial applications.

Copper Nanocomposites In Situ Formed from Metallic Glasses for an Efficient Catalytic Performance

Metallic glasses (MGs) with the unique long-range disordered and short-range ordered atomic structure have attracted extensive attention in the field of environmental catalysis due to their advanced catalytic capability. Herein, CuZr-based MGs are first proven to exhibit superior catalytic performance toward the degradation of organic pollutants compared to the annealed ribbons with different crystal structures; many Cu nanocomposites are gradually in situ precipitated on the surface of the ribbons. The enhanced catalytic behavior is mainly attributed to the random atomic packing structure accelerating electron transport and providing sufficient active sites. On the other hand, the active species, for example, ·OH, ·O₂^-, and Cu(III), are generated through an activation reaction between Cu/Cu₂O nanocomposites and H₂O₂ molecules for the catalytic degradation process. Additionally, further investigation indicated that CuZr-based MGs also present superior stability and durability along with an approximate 96% degradation efficiency within 10 min at the 10th run. This research can successfully explain why MGs have a little higher catalytic reactivity than their crystalline counterparts, and more importantly, it will provide a new strategy for the preparation of catalytic materials for wastewater treatment.

Designing High Entropy Bulk Metallic Glass (HE-BMG) by Similar Element Substitution/Addition

In this paper, we report that two newly designed high entropy bulk metallic glasses (HE-BMGs), Ti₂₀Hf₂₀Cu₂₀Ni₂₀Be₂₀ with a critical diameter of 2 mm, and Ti_16.7Zr_16.7Nb_16.7Cu_16.7Ni_16.7Be_16.7 with a critical diameter of 1.5 mm, can be fabricated by copper mold casting method. These newly developed HE-BMGs exhibited a high fracture strength over 2300 MPa. The glass forming ability and atomic size distribution characteristics of the HE-BMGs are discussed in detail. Moreover, a parameter δ' was proposed to evaluate the atomic size distribution characteristics in different HEAs. It showed that this new parameter is closely related to the degree of lattice distortion and phase selection of high-entropy alloys. Adjusting the value of δ' parameter by similar element substitution/addition would be beneficial for designing high entropy bulk metallic glasses.