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Catalysts
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Advances in the Manufacturing of Structured Catalysts and Microchannel Reactors
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Advances in the Manufacturing of Structured Catalysts and Microchannel Reactors

A special issue of Catalysts (ISSN 2073-4344). This special issue belongs to the section "Catalytic Materials".

Deadline for manuscript submissions: closed (30 April 2023) | Viewed by 7450

Special Issue Editors

Dr. Marcela Martinez Tejada

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Guest Editor
Departamento de Química Inorgánica - Instituto de Ciencia de Materiales de Sevilla, Universidad de Sevilla - CSIC, Av. Américo Vespucio 49, 41092 Sevilla, Spain
Interests: heterogeneous catalysis; catalysis by noble metals; catalysis by transition metals; structured reactors; H2 production and clean-up; steam reforming; water–gas shift reaction; CO oxidation; CO preferential oxidation; CO and CO2 methanation; CO2 capture; carbon-based catalysts
Special Issues, Collections and Topics in MDPI journals
Dr. Miguel Angel Centeno

E-Mail Website
Guest Editor
Departamento de Química Inorgánica, Instituto de Ciencia de Materiales de Sevilla, Centro Mixto CSIC—Universidad de Sevilla, 41092 Sevilla, Spain
Interests: heterogeneous catalysis; structured catalysts; H2; biomass; CO2; microreactors; environment and energy; carbon-based catalysts
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Structured catalysts and microchannel reactors have great potential in fast, heterogeneously catalyzed gas and liquid phase reactions due to their superior mass and heat transfer properties, which are key for process intensification in chemical reactions, favoring higher conversion, selectivity, and yield towards desired products. However, differents challenges remain before fully exploiting the kinetic potential of catalysts in microchanells. First, traditional catalyst-preparation methods, such as impregnation, would result in the poor dispersion of active species on reactor walls. Second, adhesion, chemical compatibility, reactor size implication, stacking schemes, modular approaches, and temperature/pressure requirements should be carefully studied before the selection of a method used to achieve the homogeneous distribution of a catalytic material. A good selection of these parameters favor the physicochemical stability of the coatings under reaction conditions, motivating the search for new preparations methods.

This Special Issue will focus on the manufacturing of structured catalysts and microchannel reactors of mono-, bi, and tri-metallic formulations of any supported catalysts on carbon, glass, quartz, polymeric, and metal substrates. The application of structured catalysts in diverse heterogeneous reactions, complete studies on their preparation, and the characterization of structured supported catalysts are welcome, as are novel insights based on additive manufacturing technique, operando and/or kinetics studies of mechanisms, and catalytic performance.

Dr. Marcela Martinez Tejada
Dr. Miguel Angel Centeno
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Catalysts is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • structured catalysts
  • microchannel reactors
  • microreactor fabrication
  • coating strategies
  • quartz microreactors
  • polymeric microreactors
  • metallic microreactors
  • additive manufacturing (AM)
  • monometallic structured catalysts
  • bimetallic structured catalysts
  • trimetallic structured catalysts
  • carbon structured catalysts

Published Papers (5 papers)

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Research

17 pages, 3963 KiB  
Article
New 3D Printing Strategy for Structured Carbon Devices Fabrication
by Gabriel Delgado-Martín, Nicolás Rodríguez, María Isabel Domínguez, Yazmin Yaneth Agámez-Pertuz, Marcela Martínez Tejada, Estela Ruíz-López, Svetlana Ivanova and Miguel Ángel Centeno
Catalysts 2023, 13(7), 1039; https://doi.org/10.3390/catal13071039 - 26 Jun 2023
Viewed by 947
Abstract
This work shows a new method for the preparation of 100% carbon-structured devices. The method is based on resorcinol-formaldehyde polymerization, using starch as a binder with the addition of a certain amount of external carbon source before polymerization. Molds obtained by 3D printing [...] Read more.
This work shows a new method for the preparation of 100% carbon-structured devices. The method is based on resorcinol-formaldehyde polymerization, using starch as a binder with the addition of a certain amount of external carbon source before polymerization. Molds obtained by 3D printing are used to shape the structured devices in the desired shape, and the ultimate pyrolysis step consolidates and produces the carbonaceous devices. The proposed method allows obtaining supports with different textural and surface properties varying the carbonaceous source, the solvent, or the pyrolysis conditions, among other factors. The as-obtained devices have demonstrated their usefulness as palladium supports for the gas-phase formic acid dehydrogenation reaction. The monolith shows a high conversion of formic acid (81% according to H2 production) and a high selectivity towards hydrogen production at mild temperatures (80% at 423 K). Full article
(This article belongs to the Special Issue Advances in the Manufacturing of Structured Catalysts and Microchannel Reactors)
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17 pages, 1137 KiB  
Article
Transition of the Flow Regime Inside of Monolith Microchannel Reactors Fed with Highly Turbulent Flow
by Gonzalo Garretón, Lindley Maxwell and Iván Cornejo
Catalysts 2023, 13(6), 938; https://doi.org/10.3390/catal13060938 - 26 May 2023
Viewed by 1531
Abstract
This paper investigates the flow behaviour of monolith microchannels. Specifically, the study characterizes the flow regime within in-series monolith channels where highly turbulent flow approaches them but inside of the channels, the Reynolds number is subcritical. Results from LES and a transitional RANS [...] Read more.
This paper investigates the flow behaviour of monolith microchannels. Specifically, the study characterizes the flow regime within in-series monolith channels where highly turbulent flow approaches them but inside of the channels, the Reynolds number is subcritical. Results from LES and a transitional RANS model are compared to those obtained when directly assuming laminar flow inside of the channels. A space-resolved model of channels placed in series and channel Reynolds numbers ranging from 50 to 300 are considered. The results show that the flow pattern in is almost identical in the two channels and that the frequency of fluctuations tends to increase with the Reynolds number. The flow regime in both channels is unsteady laminar, containing a wide spectrum of frequencies. The tested transitional RANS model (k-kL-ω) is unable to capture the velocity fluctuations predicted by LES. Despite the differences in the velocity field prediction, the pressure drop estimation from all models is practically the same. This study provides insights into the flow behaviour of monolith reactors and is useful for reactor design and optimization. Full article
(This article belongs to the Special Issue Advances in the Manufacturing of Structured Catalysts and Microchannel Reactors)
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13 pages, 1768 KiB  
Article
Microreactor Based on Trimetallic Nano-Oxides Obtained by In Situ Growth from German Silver
by Ana P. Cabello, Mayra A. Franco Murcia, María A. Ulla and Juan M. Zamaro
Catalysts 2023, 13(6), 932; https://doi.org/10.3390/catal13060932 - 25 May 2023
Viewed by 916
Abstract
Nanostructured films of copper, zinc, and nickel oxides were obtained from a controlled oxidation of the ternary nickel silver (Cu-Zn-Ni) substrates through a one-pot, green, and low temperature vapor-based treatment. Brief contact of the alloy with ammonia and hydrogen peroxide vapors at room [...] Read more.
Nanostructured films of copper, zinc, and nickel oxides were obtained from a controlled oxidation of the ternary nickel silver (Cu-Zn-Ni) substrates through a one-pot, green, and low temperature vapor-based treatment. Brief contact of the alloy with ammonia and hydrogen peroxide vapors at room temperature originates a mixture of nanometric copper, zinc, and nickel oxides at its surface. The growths evolve with time and temperature, generating a layered film with highly dispersed copper nano-oxides/hydroxides on a base of zinc and nickel oxides. The composition, configuration, and way of obtaining these films make them green catalysts, which are highly active and stable for a carbon monoxide oxidation reaction. Full article
(This article belongs to the Special Issue Advances in the Manufacturing of Structured Catalysts and Microchannel Reactors)
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14 pages, 4024 KiB  
Article
The 3D-Printing Fabrication of Multichannel Silicone Microreactors for Catalytic Applications
by Alejandro Ibáñez-de-Garayo, Mikel Imizcoz, Maitane Maisterra, Fernando Almazán, Diego Sanz, Fernando Bimbela, Alfonso Cornejo, Ismael Pellejero and Luis M. Gandía
Catalysts 2023, 13(1), 157; https://doi.org/10.3390/catal13010157 - 09 Jan 2023
Cited by 3 | Viewed by 1986
Abstract
Microstructured reactors (MSRs) are especially indicated for highly demanding heterogeneous catalysis due to the small channel dimensions that minimize diffusional limitations and enhance mass and heat transport between the fluid and the catalyst. Herein, we present the fabrication protocol of the fused filament [...] Read more.
Microstructured reactors (MSRs) are especially indicated for highly demanding heterogeneous catalysis due to the small channel dimensions that minimize diffusional limitations and enhance mass and heat transport between the fluid and the catalyst. Herein, we present the fabrication protocol of the fused filament 3D printing of silicone monolithic microreactors based on a multichannel design. Microchannels of 200 to 800 µm in width and up to 20 mm in length were developed following the scaffold-removal procedure using acrylonitrile butadiene styrene (ABS) as the material for the 3D-printed scaffold fabrication, polydimethylsiloxane (PDMS) as the building material, and acetone as the ABS removing agent. The main printing parameters such as temperature and printing velocity were optimized in order to minimize the bridging effect and filament collapsing and intercrossing. Heterogeneous catalysts were incorporated into the microchannel walls during fabrication, thus avoiding further post-processing steps. The nanoparticulated catalyst was deposited on ABS scaffolds through dip coating and transferred to the microchannel walls during the PDMS pouring step and subsequent scaffold removal. Two different designs of the silicone monolithic microreactors were tested for four catalytic applications, namely liquid-phase 2-nitrophenol photohydrogenation and methylene blue photodegradation in aqueous media, lignin depolymerization in ethanol, and gas-phase CO2 hydrogenation, in order to investigate the microreactor performance under different reaction conditions (temperature and solvent) and establish the possible range of applications. Full article
(This article belongs to the Special Issue Advances in the Manufacturing of Structured Catalysts and Microchannel Reactors)
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22 pages, 5926 KiB  
Article
Ceramic Papers as Structured Catalysts: Preparation and Application for Particulate Removal
by Sabrina A. Leonardi, Eduardo E. Miró and Viviana G. Milt
Catalysts 2022, 12(10), 1153; https://doi.org/10.3390/catal12101153 - 01 Oct 2022
Viewed by 1175
Abstract
Fibers represent a type of structure of great interest in catalysis since they combine high area to volume ratio and can be fabricated from many types of materials, such as ceramic oxides, polymers, and alloys. They can be used in isolated form or [...] Read more.
Fibers represent a type of structure of great interest in catalysis since they combine high area to volume ratio and can be fabricated from many types of materials, such as ceramic oxides, polymers, and alloys. They can be used in isolated form or structured, as in the case of the ceramic papers synthesized in this work, following a modified papermaking technique. The addition of cationic and anionic polyelectrolytes improved the retention of ceramic fibers during the ceramic paper formation stage by adsorption processes, through the formation of floccules. In the complex aqueous system containing charged macromolecules, the amounts of polyelectrolytes to be added were determined by titrations. To enhance mechanical properties of ceramic papers, different classes of nanoparticle suspensions can be used as binders. As a novel alternative, we have used different borate-type compounds. Among them, we selected natural ulexite, which was purified and used as a binder of ceramic fibers. In order to improve mechanical resistance and flexibility, measured from tensile indexes and elastic module, the amounts of NaCaB5O6(OH)6.5H2O and the calcination temperature were varied. In this contribution, to take advantage of the unique characteristics of the ulexite-containing ceramic papers, they were impregnated with Co,Ce and Co,Ba,K and tested for diesel soot combustion. Full article
(This article belongs to the Special Issue Advances in the Manufacturing of Structured Catalysts and Microchannel Reactors)
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