Oak Ridge National Laboratory and Dartmouth College have developed a 3D printing method for manufacturing structured catalysts with improved resolution and performance. Designed to address key limitations in continuous flow reactors, this innovation enhances conversion efficiency for processes such as catalytic pyrolysis of waste into jet fuel.
Description
This invention introduces a 3D printing approach for fabricating structured catalysts that overcome the mass and heat transfer limitations—and high pressure drops—associated with traditional pelletized catalysts. Using an optimized direct ink writing process, the catalysts are printed with specific geometries to improve flow dynamics and durability. The method increases catalyst loading to 44 percent (up from 26 percent), eliminates post-treatment steps, and enables the use of nozzle sizes as small as 0.6 mm for improved printing resolution. The mechanical strength of the printed catalysts has been demonstrated, and various parameters such as layer thickness, extrusion rate, and print speed have been optimized. The structured catalysts are being evaluated for catalytic pyrolysis of waste materials, including plastics and biomass, to produce jet fuel. This approach enables custom catalyst designs that better match specific reactor requirements while reducing material waste and manufacturing costs.
Benefits
- Reduces mass and heat transfer limitations and pressure drop in continuous flow reactors
- Enables catalyst geometries tailored to specific reactor designs
- Increases catalyst loading and eliminates post-processing steps
- Improves conversion efficiency and product yield
Applications and Industries
- Biofuel production via catalytic pyrolysis of waste materials
- Catalyst manufacturing for renewable energy and chemical industries
- Continuous flow reactor technology providers seeking custom catalyst integration
Contact
To learn more about this technology, email [email protected] or call 865-574-1051.
Researchers
Contact
To learn more about this technology, email [email protected] or call 865-574-1051.