3D printing in chemical engineering and catalytic technology: structured catalysts, mixers and reactors

Depletion Flocculation of High Internal Phase Pickering Emulsion Inks: A Colloidal Engineering Approach to Develop 3D Printed Porous Scaffolds with Tunable Bioactive Delivery

Flocculation is a type of aggregation where the surfaces of approaching droplets are still at distances no closer than a few nanometers while still remaining in close proximity. In a high internal-phase oil-in-water (O/W) emulsion, the state of flocculation affects the bulk flow behavior and viscoelasticity, which can consequently control the three-dimensional (3D)-printing process and printing performance. Herein, we present the assembly of O/W Pickering high-internal-phase emulsions (Pickering-HIPEs) as printing inks and demonstrate how depletion flocculation in such Pickering-HIPE inks can be used as a facile colloidal engineering approach to tailor a porous 3D structure suitable for drug delivery. Pickering-HIPEs were prepared using different levels of cellulose nanocrystals (CNCs), co-stabilized using "raw" submicrometer-sized sustainable particles from a biomass-processing byproduct. In the presence of this sustainable particle, the higher CNC contents facilitated particle-induced depletion flocculation, which led to the formation of a mechanically robust gel-like ink system. Nonetheless, the presence of adsorbed particles on the surface of droplets ensured their stability against coalescence, even in such a highly aggregated system. The gel structures resulting from the depletion phenomenon enabled the creation of high-performance printed objects with tunable porosity, which can be precisely controlled at two distinct levels: first, by introducing voids within the internal structure of filaments, and second, by generating cavities (pore structures) through the elimination of the water phase. In addition to printing efficacy, the HIPEs could be applied for curcumin delivery, and in vitro release kinetics demonstrated that the porous 3D scaffolds engineered for the first time using depletion-flocculated HIPE inks played an important role in 3D scaffold disintegration and curcumin release. Thus, this study offers a unique colloidal engineering approach of using depletion flocculation to template 3D printing of sustainable inks to generate next-generation porous scaffolds for personalized drug deliveries.

High-Resolution Additive Manufacturing of a Biodegradable Elastomer with A Low-Cost LCD 3D Printer

Artificial organs and organs-on-a-chip (OoC) are of great clinical and scientific interest and have recently been made by additive manufacturing, but depend on, and benefit from, biocompatible, biodegradable, and soft materials. Poly(octamethylene maleate (anhydride) citrate (POMaC) meets these criteria and has gained popularity, and as in principle, it can be photocured and is amenable to vat-photopolymerization (VP) 3D printing, but only low-resolution structures have been produced so far. Here, a VP-POMaC ink is introduced and 3D printing of 80 µm positive features and complex 3D structures is demonstrated using low-cost (≈US$300) liquid-crystal display (LCD) printers. The ink includes POMaC, a diluent and porogen additive to reduce viscosity within the range of VP, and a crosslinker to speed up reaction kinetics. The mechanical properties of the cured ink are tuned to match the elastic moduli of different tissues simply by varying the porogen concentration. The biocompatibility is assessed by cell culture which yielded 80% viability and the potential for tissue engineering illustrated with a 3D-printed gyroid seeded with cells. VP-POMaC and low-cost LCD printers make the additive manufacturing of high resolution, elastomeric, and biodegradable constructs widely accessible, paving the way for a myriad of applications in tissue engineering and 3D cell culture as demonstrated here, and possibly in OoC, implants, wearables, and soft robotics.

Tuning the Mechanical Properties of 3D-printed Objects by the RAFT Process: From Chain-Growth to Step-Growth

Photoinduced 3D printing based on the reversible addition-fragmentation chain transfer (RAFT) process has emerged as a robust method for creating diverse functional materials. However, achieving precise control over the mechanical properties of these printed objects remains a critical challenge for practical application. Here, we demonstrated a RAFT step-growth polymerization of a bifunctional xanthate and bifunctional vinyl acetate. Additionally, we demonstrated photoinduced 3D printing through RAFT step-growth polymerization with a tetrafunctional xanthate and a bifunctional vinyl acetate. By adjusting the molar ratio of the components in the printing resins, we finely tuned the polymerization mechanism from step-growth to chain-growth. This adjustment resulted in a remarkable range of tunable Young's moduli, ranging from 7.6 MPa to 997.1 MPa. Moreover, post-functionalization and polymer welding of the printed objects with varying mechanical properties opens up a promising way to produce tailor-made materials with specific and tunable properties.

Photocatalytic NOx removal with TiO2-impregnated 3D-printed PET supports

In this work, we investigated the photocatalytic removal of NOx using 3D-printed supports. Monolithic supports with internal channels were fabricated by Fused Modelling Deposition (FDM) using PET as the filament feedstock. The printing parameters of the supports were optimized to maximize the exposure of the photocatalyst to UV light throughout the monolithic PET printed supports. The removal experiments were carried out in a continuous gas phase flow reactor, which was custom designed in-house incorporating a 3D printed PET support impregnated with TiO2 as photocatalyst. The impregnated and non-impregnated supports were characterized by diffuse reflectance spectrometry, SEM and AFM. The effect of several key-factors on the NOx removal capacity was investigated, including the type of PET filament (native recycled, BPET vs. glycol-modified, PETG), the type of TiO2 (P25 vs. Hombikat UV-100), the UV light source (LED vs. tubular lamps), and the number of deposited TiO2 layers. The highest NO and NOx removal were achieved by using PETG supports coated with a single layer of Hombikat UV-100 and irradiating the flat reactor from both sides using two sets of black light lamps. However, the highest selectivity toward nitrate formation was obtained when using P25 under the same experimental conditions. This work demonstrates that 3D printing is a reliable and powerful technique for fabricating photocatalytic reactive supports that can serve as a versatile platform for evaluating photocatalytic performance.

Impact of 3D printing materials on mircoalga Chlorella vulgaris

3D printing represents a key enabling technology in designing photobioreactors. It allows rapid prototyping of complex geometries at an affordable price. Yet, no study dealt with the biocompatibility of 3D printing material with microalgae. Thus microalga Chlorella vulgaris was cultivated in contact with different 3D printing materials (Acrylonitrile Butadiene Styren - ABS, PolyCarbonate Blend - PC-Blend, PolyLactic acid - PLA, and acrylate methacrylate resin). Cell status was analyzed using flow cytometry, fluorometry, and pigment profiling. Results revealed that acrylate methacrylate resin material inhibits growth, a constant rise in intracellular reactive oxygen species, and a decrease in photosynthetic apparatus functioning. On the contrary, ABS, PC-Blend, and PLA led to nominal perfromances. Nevertheless, PLA was the only material that did not induce an early onset of intracellular reactive oxygen species. Therefore, resin can be ruled out as photobioreactor material, ABS and PC-Blend could be used after a curation period, and PLA induces no detectable perturbations by the means used in this study.

Wireless Electrochemical Reactor for Accelerated Exploratory Study of Electroorganic Synthesis

Electrosynthesis is an emerging tool to construct value-added fine chemicals under mild and sustainable conditions. However, the complex apparatus required impedes the facile development of new electrochemistry in the laboratory. Herein, we proposed and demonstrated the concept of wireless electrochemistry (Wi-eChem) based on wireless power transfer technology. The core of this concept is the dual-function wireless electrochemical magnetic stirrer that provides an electrolysis driving force and mixing simultaneously in a miniaturized form factor. This Wi-eChem system allowed electrochemists to execute electrochemical reactions in a manner similar to traditional organic chemistry without handling wire connections. The controllability, reusability, and versatility were validated with a series of modern electrosynthesis reactions, including electrodecarboxylative etherification, electroreductive olefin-ketone coupling, and electrochemical nickel-catalyzed oxygen atom transfer reaction. Its remarkably simplified operation enabled its facile integration into a fully automated robotic synthesis platform to achieve autonomous parallel electrosynthesis screening.

Development of a 3D-Printable, Porous, and Chemically Active Material Filled with Silica Particles and its Application to the Fabrication of a Microextraction Device

We report on the first successful attempt to produce a silica/polymer composite with retained C18 silica sorptive properties that can be reliably printed using three-dimensional (3D) FDM printing. A 3D printer provides an exceptional tool for producing complex objects in an easy and inexpensive manner and satisfying the current custom demand of research. Fused deposition modeling (FDM) is the most popular 3D-printing technique based on the extrusion of a thermoplastic material. The lack of appropriate materials limits the development of advanced applications involving directly 3D-printed devices with intrinsic chemical activity. Progress in sample preparation, especially for complex sample matrices and when mass spectrometry is favorable, remains a vital research field. Silica particles, for example, which are commonly used for extraction, cannot be directly extruded and are not readily workable in a powder form. The availability of composite materials containing a thermoplastic polymer matrix and dispersed silica particles would accelerate research in this area. This paper describes how to prepare a polypropylene (PP)/acrylonitrile-butadiene-styrene (ABS)/C18-functionalized silica composite that can be processed by FDM 3D printing. We present a method for producing the filament as well as a procedure to remove ABS by acetone rinsing (to activate the material). The result is an activated 3D-printed object with a porous structure that allows access to silica particles while maintaining macroscopic size and shape. The 3D-printed device is intended for use in a solid-phase microextraction (SPME) procedure. The proposed composite's effectiveness is demonstrated for the microextraction of glimepiride, imipramine, and carbamazepine. The complex honeycomb geometry of the sorbent has shown to be superior to the simple tubular sorbent, which proves the benefits of 3D printing. The 3D-printed sorbent's shape and microextraction parameters were fine-tuned to provide satisfactory recoveries (33-47%) and high precision (2-6%), especially for carbamazepine microextraction.

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.

FOMSy: 3D-printed flexible open-source microfluidic system and flow synthesis of PET-tracer

In this work, we introduce a low-cost open-source flow system that includes a dual syringe pump with implemented pressure sensor and back pressure regulator. The entire system can be built for around 500 €. Commercially available flow systems can be very expensive with equipment starting at, but often greatly exceeding, 10,000 €. This high price of entry makes such technology prohibitively expensive for many research groups. Such systems stand to benefit the emerging academic pharmaceutical field by providing the experience and availability of reliable and affordable solutions. To implement accessible flow chemistry at research facilities, the systems must be made affordable. In addition, space in research laboratories is usually limited and commercially available flow systems can be very bulky. Having a compact and individually adjustable system is thus beneficial, with 3D printing technology offering the solution. Our compact 3D-printed system meets the needs of many applications in flow chemistry research as well as educational requirements for universities. As a proof of concept, we conceptualized, developed, and tested a custom flow system that can be used to synthesize [18F]2-fluoro-2-desoxy-d-glucose ([18F]FDG), the most commonly used PET-tracer. This system was designed to perform the typical functions and operations required in radiotracer production i.e. radiofluorination, dilution, SPE-trapping, deprotection, and SPE-elution. With this proof-of-concept in hand, the system can be easily customized to produce other radiopharmaceuticals.

Overflow Control for Sustainable Development by Superwetting Surface with Biomimetic Structure

Liquid flowing around a solid edge, i.e., overflow, is a commonly observed flow behavior. Recent research into surface wetting properties and microstructure-controlled overflow behavior has attracted much attention. Achieving controllable macroscale liquid dynamics by manipulating the micro-nanoscale liquid overflow has stimulated diverse scientific interest and fostered widespread use in practical applications. In this review, we outline the evolution of overflow and present a critical survey of the mechanism of surface wetting properties and microstructure-controlled liquid overflow in multilength scales ranging from centimeter to micro and even nanoscale. We summarize the latest progress in utilizing the mechanisms to manipulate liquid overflow and achieve macroscale liquid dynamics and in emerging applications to manipulate overflow for sustainable development in various fields, along with challenges and perspectives.

Additive manufacturing of microstructured reactors for organometallic catalytic reactions

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.

A Comprehensive Review on Graphitic Carbon Nitride for Carbon Dioxide Photoreduction

Inspired by natural photosynthesis, harnessing the wide range of natural solar energy and utilizing appropriate semiconductor-based catalysts to convert carbon dioxide into beneficial energy species, for example, CO, CH₄ , HCOOH, and CH₃ COH have been shown to be a sustainable and more environmentally friendly approach. Graphitic carbon nitride (g-C₃ N₄ ) has been regarded as a highly effective photocatalyst for the CO₂ reduction reaction, owing to its cost-effectiveness, high thermal and chemical stability, visible light absorption capability, and low toxicity. However, weaker electrical conductivity, fast recombination rate, smaller visible light absorption window, and reduced surface area make this catalytic material unsuitable for commercial photocatalytic applications. Therefore, certain procedures, including elemental doping, structural modulation, functional group adjustment of g-C₃ N₄ , the addition of metal complex motif, and others, may be used to improve its photocatalytic activity towards effective CO₂ reduction. This review has investigated the scientific community's perspectives on synthetic pathways and material optimization approaches used to increase the selectivity and efficiency of the g-C₃ N₄ -based hybrid structures, as well as their benefits and drawbacks on photocatalytic CO₂ reduction. Finally, the review concludes a comparative discussion and presents a promising picture of the future scope of the improvements.

Advanced Formulations Based on Poly(ionic liquid) Materials for Additive Manufacturing

Innovation in materials specially formulated for additive manufacturing is of great interest and can generate new opportunities for designing cost-effective smart materials for next-generation devices and engineering applications. Nevertheless, advanced molecular and nanostructured systems are frequently not possible to integrate into 3D printable materials, thus limiting their technological transferability. In some cases, this challenge can be overcome using polymeric macromolecules of ionic nature, such as polymeric ionic liquids (PILs). Due to their tuneability, wide variety in molecular composition, and macromolecular architecture, they show a remarkable ability to stabilize molecular and nanostructured materials. The technology resulting from 3D-printable PIL-based formulations represents an untapped array of potential applications, including optoelectronic, antimicrobial, catalysis, photoactive, conductive, and redox applications.

Systematic evaluation of agarose- and agar-based bioinks for extrusion-based bioprinting of enzymatically active hydrogels

Extrusion-based 3D bioprinting enables the production of customized hydrogel structures that can be employed in flow reactors when printing with enzyme-containing inks. The present study compares inks based on either low-melt agarose or agar at different concentrations (3-6%) and loaded with the thermostable enzyme esterase 2 from the thermophilic organism Alicyclobacillus acidocaldarius (AaEst2) with regard to their suitability for the fabrication of such enzymatically active hydrogels. A customized printer setup including a heatable nozzle and a cooled substrate was established to allow for clean and reproducible prints. The inks and printed hydrogel samples were characterized using rheological measurements and compression tests. All inks were found to be sufficiently printable to create lattices without overhangs, but printing quality was strongly enhanced at 4.5% polymer or more. The produced hydrogels were characterized regarding mechanical strength and diffusibility. For both properties, a strong correlation with polymer concentration was observed with highly concentrated hydrogels being more stable and less diffusible. Agar hydrogels were found to be more stable and show higher diffusion rates than comparable agarose hydrogels. Enzyme leaching was identified as a major drawback of agar hydrogels, while hardly any leaching from agarose hydrogels was detected. The poor ability of agar hydrogels to permanently immobilize enzymes indicates their limited suitability for their employment in perfused biocatalytic reactors. Batch-based activity assays showed that the enzymatic activity of agar hydrogels was roughly twice as high as the activity of agarose hydrogels which was mostly attributed to the increased amount of enzyme leaching. Agarose bioinks with at least 4.5% polymer were identified as the most suitable of the investigated inks for the printing of biocatalytic reactors with AaEst2. Drawbacks of these inks are limited mechanical and thermal stability, not allowing the operation of a reactor at the optimum temperature of AaEst2 which is above the melting point of the employed low-melt agarose.

Continuous Flow Biocatalytic Reductive Amination by Co-Entrapping Dehydrogenases with Agarose Gel in a 3D-Printed Mould Reactor

Herein, we show how the merge of biocatalysis with flow chemistry aided by 3D-printing technologies can facilitate organic synthesis. This concept was exemplified for the reductive amination of benzaldehyde catalysed by co-immobilised amine dehydrogenase and formate dehydrogenase in a continuous flow micro-reactor. For this purpose, we investigated enzyme co-immobilisation by covalent binding, or ion-affinity binding, or entrapment. Entrapment in an agarose hydrogel turned out to be the most promising solution for this biocatalytic reaction. Therefore, we developed a scalable and customisable approach whereby an agarose hydrogel containing the co-entrapped dehydrogenases was cast in a 3D-printed mould. The reactor was applied to the reductive amination of benzaldehyde in continuous flow over 120 h and afforded 47 % analytical yield and a space-time yield of 7.4 g L day-1 using 0.03 mol% biocatalysts loading. This work also exemplifies how rapid prototyping of enzymatic reactions in flow can be achieved through 3D-printing technology.

Design, Heat Transfer, and Visualization of the Milli-Reactor by CFD and ANN

This paper proposes a milli-reactor design method incorporating reactor runaway criteria. Based on Computational Fluid Dynamic (CFD) simulation, neural networks are applied to obtain the optimal reactor structure according to the target reaction requirements. Varma’s theory, the critical Nusselt number for stable operation of the flow reactor, is derived. Inserts of the multi-blade structure are designed and investigated to enhance mixing and heat transfer performance. The flow field and heat transfer capacities are obtained by CFD calculations in the range of Re 50–1800. The internal components increase the heat transfer performance up to 21 times, and the pressure drop up to 16 times. The inclined angle of the blade is recommended to be 45°, which can effectively improve heat transfer without generating excessive pressure drop. By partial least squares regression (PLS) analysis, Re and the number of blades are the most critical factors affecting heat transfer, and the five blades and smaller tilt angles are recommended. The CFD calculation results are in good agreement with the Particle Image Velocimetry (PIV) experimental results.

Solvent-Free Hydrogenation of Squalene Using Parts per Million Levels of Palladium Supported on Carbon Nanotubes: Shift from Batch Reactor to Continuous-Flow System

The transition from batch catalytic processes to continuous flow processes requires highly active and stable catalysts that still need to be developed. The preparation and characterization of catalysts where palladium single atoms and nanoparticles are simultaneously present on carbon nanotubes were recently reported by us. These catalysts are considerably more active than commercial or previously described catalysts for the liquid phase hydrogenation of terpenes. Herein is shown that under solvent-free conditions, squalene (SQE) could be converted into squalane (SQA,>98 %) using only 300 ppm of Pd in less than 1.4 h at 20 bar H₂ and 120 °C. Catalyst stability was assessed in a lab-scale flow reactor, and long-term experiments led to turnover number (TON) higher than 300000 without any detectable loss in the activity. Then, the implementation of this catalyst in a commercial intensified continuous-flow milli-reactor pilot was achieved. High purity SQA (>98 %) could be obtained by continuous hydrogenation of solvent-free SQE at 180 °C and 30 bar H₂ with a contact time below 15 min. A production capacity of 3.6 kg per day of SQA could be obtained with an effective reactor volume (V_R ) of 43.2 mL for this complex 3 phase reaction. Large-scale production can now be foreseen thanks to seamless scale-up provided by the continuous flow pilot supplier.

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.

A 3D Printer in the Lab: Not Only a Toy

Although 3D printers are becoming more common in households, they are still under-represented in many laboratories worldwide and regarded as toys rather than as laboratory equipment. This short review wants to change this conservative point of view. This mini-review focuses on fused deposition modeling printers and what happens after acquiring your first 3D printer. In short, these printers melt plastic filament and deposit it layer by layer to create the final object. They are getting cheaper and easier to use, and nowadays it is not difficult to find good 3D printers for less than €500. At such a price, a 3D printer is one, if not the most, versatile piece of equipment you can have in a laboratory.

Customizing continuous chemistry and catalytic conversion for carbon–carbon cross-coupling with 3dP

Support structures of various materials are used to enhance the performance of catalytic process chemistry. Typically, fixed bed supports contain regular channels enabling high throughput because of the low pressure drop that accompanies high flow rates. However, many fixed bed supports have a low surface-area-to-volume ratio resulting in poor contact between the substrates and catalyst. Three dimensional polymer printing (3dP) can be used to overcome these disadvantages by offering precise control over key design parameters of the fixed bed, including total bed surface area, as well as accommodating system integration features that are compatible with continuous flow chemistry. Additionally, 3dP allows for optimization of the catalytic process based on extrinsic constraints (e.g. operating pressure) and digital design features. These design parameters together with the physicochemical characterization and optimization of catalyst loading can be tuned to prepare customizable reactors based on objectives for substrate conversion and desired throughput. Using a Suzuki (carbon–carbon) cross-coupling reaction catalyzed by palladium, we demonstrate our integrated approach. We discuss key elements of our strategy including the rational design of hydrodynamics, immobilization of the heterogeneous catalyst, and substrate conversion. This hybrid digital-physical approach enables a range of pharmaceutical process chemistries spanning discovery to manufacturing scale.

Structured Reactors Based on 3D Fe/SiC Catalysts: Understanding the Effects of Mixing

The application of structured reactors provides a number of advantages in chemical processes. In this paper, two different three-dimensional (3D) Fe/SiC catalysts with a square cell geometry have been manufactured by Robocasting: monoliths (D = 14 and H = 15 mm) and meshes (D = 24 and H = 2 mm) and studied in the catalytic phenol oxidation by hydrogen peroxide (H₂O₂) for the sustainable production of dihydroxybenzenes (DHBZ). The fluid dynamics, catalytic performance, reaction rates, external mass transport limitation, and catalyst stability have been compared in three different reactors, monolithic fixed-bed reactor, multimesh fixed-bed reactor, and monolithic stirrer reactor, at selected operating conditions. The results show that the mechanical stirring of the 3D Fe/SiC monoliths avoids the external mass transfer limitation caused by the presence of oxygen bubbles in the channels (produced from the HO _x · species in autoscavenging radical reactions). In addition, the backmixing has a positive effect on the efficient consumption of H₂O₂ but an adverse effect on the phenol selectivity to DHBZ since they are overoxidized to tar products at longer contact times. On the other hand, the wall porosity, and not the backmixing, affects the susceptibility of the 3D Fe/SiC catalyst to the Fe leaching, as occurs in the mesh structures. In conclusion, the monoliths operating under plug-flow and external mass transfer limitation in the monolithic fixed-bed reactor (MFB) provide an outstanding phenol selectivity to DHBZ and catalyst stability.

In Search of an Effective Workability Zone during the 3D Printing of Polymeric Periodic Open Cellular Structures Potentially Useful as Microreactors

The question of how easy the transition is between design and manufacturing by the 3D printing of periodic open cellular structures occurs from the analysis of cases in which additive manufacturing and heterogeneous catalysis merge. The synergy between these two fields suggests that one of the great advantages that the catalysis of this manufacturing methodology can take advantage of is the obtaining of advanced designs that would allow improving the processes from the geometry of the reactors. However, not all 3D-printing techniques offer the same degree of resolution, and this uncertainty grows when using more complex materials to work with, such as ceramics or metals. Therefore, the present work seeks to answer this question by finding experimentation strategies, starting with a simple case study inspired by the additive manufacturing–catalysis combination, in which a ceramic polymer resin of high thermal resistance is used to obtain POCSs that are potentially useful in thermochemical or adsorption processes. This exploration concludes on the need to define limits for what we have called an “effective work zone” that combines both design criteria and the real possibility of printing and manipulating the pieces, making sweeps in structural parameters such as cell size and the diameter of struts in the POCS. Similarly, the possibility of coating these systems with inorganic oxides is explored, using a generic oxide (Al2O3) to analyse this scenario. Finally, a cartridge-type assembly of these systems is proposed so that they can be explored in future processes by other researchers.

Tuning the catalytic acidity in Al2O3 nanofibers with mordenite nanocrystals for dehydration reactions

Alumina (Al2O3) is one of the most used supports in the chemical industry due to its exceptional thermal stability, surface area, and acidic properties. Mesoscopic structured alumina with adequate acidic properties is important in catalysis to enhance the selectivity and conversion of certain reactions and processes. This study introduces a synthetic method based on electrospinning to produce Al2O3 nanofibers (ANFs) with zeolite mordenite (MOR) nanocrystals (hereafter, hybrid ANFs) to tune the textural and surface acidity properties. The hybrid ANFs with electrospinning form a non-woven network with macropores. ANF-HMOR, i.e., ANFs containing protonated mordenite (HMOR), shows the highest total acidity of ca. 276 μmol g-1 as determined with infrared spectroscopy using pyridine as a molecular probe (IR-Py). IR-Py results reveal that Lewis acid sites are prominently present in the hybrid ANFs. Brønsted acid sites are also observed in the hybrid ANFs and are associated with the HMOR presence. The functionality of hybrid ANFs is evaluated during methanol dehydration to dimethyl ether (DME). The proof of concept reaction reveals that ANF-HMOR is the more active and selective catalyst with 87% conversion and nearly 100% selectivity to DME at 573 K. The results demonstrate that the textural properties and the acid site type and content can be modulated in hybrid ANF structures, synergistically improving the selectivity and conversion during the methanol dehydration reaction. From a broader perspective, our results promote the utilization of hybrid structural materials as a means to tune chemical reactions selectively.

Glycerol Is Converted into Energy and Carbonyl Compounds in a 3D-Printed Microfluidic Fuel Cell: In Situ and In Operando Bi-Modified Pt Anodes

The combination of energy and chemical conversion can be achieved by designing glycerol fuel cells. However, the anode must promote the reaction at onset potentials low enough to allow a spontaneous reaction, when coupled to the cathodic reaction, and must be selective. Here, we build a three-dimensional (3D)-printed glycerol microfluidic fuel cell that produces power concomitantly to glycolate and formate at zero bias. The balance between energy and the two carbonyl compounds is tuned by decorating the Pt/C/CP anode in situ (before feeding the cell reactants) or in operando (while feeding the cell with reactants) with Bi. The Bi-modified anodes improve glycerol conversion and output power while decreasing the formation of the carbonyl compounds. The in operando method builds dendrites of rodlike Bi oxides that are inactive for the anodic reaction and cover active sites. The in situ strategy promotes homogeneous Bi decoration, decreasing activation losses, increasing the open-circuit voltage to 1.0 V, and augmenting maximum power density 6.5 times and the glycerol conversion to 72% at 25 °C while producing 0.2 mmoL L^-1 of glycolate and formate (each) at 100 μL min^-1. Such a performance is attributed to the low CO poisoning of the anode, which leads the glycerol electrooxidation toward a more complete reaction, harvesting more electrons at the device. Printing the microfluidic fuel cell takes 23 min and costs ∼US$1.85 and can be used for other coupled reactions since the methods of modification presented here are applied to any existing and assembled systems.

3D-printed electrochemical platform with multi-purpose carbon black sensing electrodes

The 3D printing is described of a complete and portable system comprising a batch injection analysis (BIA) cell and an electrochemical platform with eight sensing electrodes. Both BIA and electrochemical cells were printed within 3.4 h using a multimaterial printer equipped with insulating, flexible, and conductive filaments at cost of ca. ~ U$ 1.2 per unit, and their integration was based on a threadable assembling without commercial component requirements. Printed electrodes were exposed to electrochemical/Fenton pre-treatments to improve the sensitivity. Scanning electron microscopy and electrochemical impedance spectroscopy measurements upon printed materials revealed high-fidelity 3D features (90 to 98%) and fast heterogeneous rate constants ((1.5 ± 0.1) × 10⁻³ cm s⁻¹). Operational parameters of BIA cell were optimized using a redox probe composed of [Fe(CN)₆]^4−/3− under stirring and the best analytical performance was achieved using a dispensing rate of 9.0 µL s⁻¹ and an injection volume of 2.0 µL. The proof of concept of the printed device for bioanalytical applications was evaluated using adrenaline (ADR) as target analyte and its redox activities were carefully evaluated through different voltammetric techniques upon multiple 3D-printed electrodes. The coupling of BIA system with amperometric detection ensured fast responses with well-defined peak width related to the oxidation of ADR applying a potential of 0.4 V vs Ag. The fully 3D-printed system provided suitable analytical performance in terms of repeatability and reproducibility (RSD ≤ 6%), linear concentration range (5 to 40 µmol L⁻¹; R² = 0.99), limit of detection (0.61 µmol L⁻¹), and high analytical frequency (494 ± 13 h⁻¹). Lastly, artificial urine samples were spiked with ADR solutions at three different concentration levels and the obtained recovery values ranged from 87 to 118%, thus demonstrating potentiality for biological fluid analysis. Based on the analytical performance, the complete device fully printed through additive manufacturing technology emerges as powerful, inexpensive, and portable tool for electroanalytical applications involving biologically relevant compounds.

Applicability of Selected 3D Printing Materials in Electrochemistry

This manuscript investigates the chemical and structural stability of 3D printing materials (3DPMs) frequently used in electrochemistry. Four 3D printing materials were studied: Clear photopolymer, Elastic photopolymer, PET filament, and PLA filament. Their stability, solubility, structural changes, flexibility, hardness, and color changes were investigated after exposure to selected organic solvents and supporting electrolytes. Furthermore, the available potential windows and behavior of redox probes in selected supporting electrolytes were investigated before and after the exposure of the 3D-printed objects to the electrolytes at various working electrodes. Possible electrochemically active interferences with an origin from the 3DPMs were also monitored to provide a comprehensive outline for the use of 3DPMs in electrochemical platform manufacturing.

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.

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.

Digital Light Processing 3D Printing of Enhanced Polymers via Interlayer Welding

Digital light processing (DLP) 3D printing is advantageous in high printing efficiency and printing resolution for fabricating complex structures across various applications. However, the layer-by-layer curing manner of DLP leads to weak interlayer adhesion and the anisotropic mechanical properties of printed objects. Here, linear polymers are introduced into commercial resins to weld the interlayer by the diffusion and entanglement of linear polymers after DLP printing via heat treatment. This introduction of linear polymers not only shows a strengthening and toughening effect on the printed objects, but also has no negative impact on the DLP printability. The tensile strengths of objects containing 4.7wt% polycaprolactone can reach up to ∼500% of that of neat samples in any printing direction. This simple strategy by adding linear polymers into printing resins provides an effective access to prepare DLP printed objects with improved mechanical properties as well as ensure printing resolution and printing efficiency. This article is protected by copyright. All rights reserved.

Technological Innovations in Photochemistry for Organic Synthesis: Flow Chemistry, High-Throughput Experimentation, Scale-up, and Photoelectrochemistry

Photoinduced chemical transformations have received in recent years a tremendous amount of attention, providing a plethora of opportunities to synthetic organic chemists. However, performing a photochemical transformation can be quite a challenge because of various issues related to the delivery of photons. These challenges have barred the widespread adoption of photochemical steps in the chemical industry. However, in the past decade, several technological innovations have led to more reproducible, selective, and scalable photoinduced reactions. Herein, we provide a comprehensive overview of these exciting technological advances, including flow chemistry, high-throughput experimentation, reactor design and scale-up, and the combination of photo- and electro-chemistry.

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.