3D printing synthesis of catalysts

Zhao, Xianhui; Karakaya, Canan; Qian, Moriko; Zou, Rongge; Zhang, Weijie; Lu, Zhou; Maiti, Debtanu; Samanta, Avik; Wan, Weiming; Liu, Xiangbei; Tiplea, Anisia; Li, Yan; Cui, Shaoqing; Wang, Chenxi; Lei, Hanwu; Bankston, Sherith; Yilmaz, Sefa; Chen, Jingguang G.; Ozcan, Soydan

doi:10.1016/j.mtsust.2024.100746

Title: 3D printing synthesis of catalysts

Journal Article · 15 March 2024 · Materials Today Sustainability

DOI: https://doi.org/10.1016/j.mtsust.2024.100746 · OSTI ID:2372624

^[1]; Karakaya, Canan ^[1]; Qian, Moriko ^[2]; Zou, Rongge ^[2]; Zhang, Weijie ^[3]; Lu, Zhou ^[3]; Maiti, Debtanu ^[4]; Samanta, Avik ^[5]; Wan, Weiming ^[6]; Liu, Xiangbei ^[7]; Tiplea, Anisia ^[7]; Li, Yan ^[7]; Cui, Shaoqing ^[8]; Wang, Chenxi ^[2]; Lei, Hanwu ^[2]; Bankston, Sherith ^[1]; Yilmaz, Sefa ^[1]; Chen, Jingguang G. ^[9]; Ozcan, Soydan ^[1]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Washington State Univ., Pullman, WA (United States)
Univ. of North Texas, Denton, TX (United States)
Idaho National Laboratory (INL), Idaho Falls, ID (United States)
Univ. of South Florida, Tampa, FL (United States)
Fritz Haber Institute of the Max Planck Society, Berlin (Germany)
Dartmouth College, Hanover, NH (United States)
Univ. of Tennessee, Knoxville, TN (United States). Center for Renewable Carbon
Columbia Univ., New York, NY (United States)

The catalyst industry generates approximately $20 billion every year globally and plays a major role in the energy production sector. Traditional industrial catalysts (e.g., pellets) typically have mass and heat transfer limitations, and cause a pressure drop in continuous-flow reactors, lowering the efficiency of the catalytic processes. 3D printing technology has evolved rapidly over the past decade, and the 3D printing of catalysts with desired geometries can address many of the above-stated challenges with traditional catalysts. However, challenges remain to be addressed and opportunities remain to be explored before the full potential in the design and 3D printing of novel catalysts can be realized. Herein this article reviews the recent development in the 3D printing of catalysts. It summarizes the 3D printing design, dimension, property, and performance of 3D printed catalysts. The applications of 3D printed catalysts, such as reforming, wastewater treatment, and CO₂ capture and removal, are discussed, with a techno-economic analysis and life cycle analysis. Future research directions and opportunities for 3D printing of catalysts are also highlighted.

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Research Organization:: Idaho National Laboratory (INL), Idaho Falls, ID (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Bioenergy Technologies Office (BETO)

Grant/Contract Number:: AC07-05ID14517; AC05-00OR22725

OSTI ID:: 2372624

Report Number(s):: INL/MIS--24-76579-Rev000

Journal Information:: Materials Today Sustainability, Journal Name: Materials Today Sustainability Journal Issue: 10 Vol. 26; ISSN 2589-2347

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Rational Design and Construction of Monolithic Ordered Mesoporous Co₃O₄@SiO₂ Catalyst by a Novel 3D Printed Technology for Catalytic Oxidation of Toluene Yao, Jianfei; Dong, Fang; Xu, Xin ACS Applied Materials & Interfaces, Vol. 14, Issue 19 https://doi.org/10.1021/acsami.2c03850	journal	May 2022
3D-Printed Zeolite Monoliths for CO ₂ Removal from Enclosed Environments Thakkar, Harshul; Eastman, Stephen; Hajari, Amit ACS Applied Materials & Interfaces, Vol. 8, Issue 41 https://doi.org/10.1021/acsami.6b09647	journal	October 2016
Formulation of Aminosilica Adsorbents into 3D-Printed Monoliths and Evaluation of Their CO ₂ Capture Performance Thakkar, Harshul; Eastman, Stephen; Al-Mamoori, Ahmed ACS Applied Materials & Interfaces, Vol. 9, Issue 8 https://doi.org/10.1021/acsami.6b16732	journal	February 2017
3D-Printed Metal–Organic Framework Monoliths for Gas Adsorption Processes Thakkar, Harshul; Eastman, Stephen; Al-Naddaf, Qasim ACS Applied Materials & Interfaces, Vol. 9, Issue 41 https://doi.org/10.1021/acsami.7b11626	journal	October 2017
Chemically Active, Porous 3D-Printed Thermoplastic Composites Evans, Kent A.; Kennedy, Zachary C.; Arey, Bruce W. ACS Applied Materials & Interfaces, Vol. 10, Issue 17 https://doi.org/10.1021/acsami.7b17565	journal	January 2018
UTSA-16 Growth within 3D-Printed Co-Kaolin Monoliths with High Selectivity for CO₂/CH₄, CO₂/N₂, and CO₂/H₂ Separation Lawson, Shane; Al-Naddaf, Qasim; Krishnamurthy, Anirduh ACS Applied Materials & Interfaces, Vol. 10, Issue 22 https://doi.org/10.1021/acsami.8b05192	journal	May 2018
Laser Sintering of Liquid Metal Nanoparticles for Scalable Manufacturing of Soft and Flexible Electronics Liu, Shanliangzi; Yuen, Michelle C.; White, Edward L. ACS Applied Materials & Interfaces, Vol. 10, Issue 33 https://doi.org/10.1021/acsami.8b08722	journal	July 2018
Design of Monolithic Supports by 3D Printing for Its Application in the Preferential Oxidation of CO (CO-PrOx) Chaparro-Garnica, Cristian Yesid; Davó-Quiñonero, Arantxa; Bailón-García, Esther ACS Applied Materials & Interfaces, Vol. 11, Issue 40 https://doi.org/10.1021/acsami.9b12731	journal	September 2019
Structured Binder-Free Al-β Zeolite for Acid-Catalyzed Dehydration Liu, Jiaxu; Li, Shanshan; Zhang, Zhenmei ACS Applied Nano Materials, Vol. 4, Issue 11 https://doi.org/10.1021/acsanm.1c02559	journal	November 2021
High Throughput Screening of 3D Printable Resins: Adjusting the Surface and Catalytic Properties of Multifunctional Architectures Manzano, J. Sebastián; Wang, Hsin; Slowing, Igor I. ACS Applied Polymer Materials, Vol. 1, Issue 11 https://doi.org/10.1021/acsapm.9b00598	journal	September 2019
Three-Dimensional Printing in Catalysis: Combining 3D Heterogeneous Copper and Palladium Catalysts for Multicatalytic Multicomponent Reactions Díaz-Marta, Antonio S.; Tubío, Carmen R.; Carbajales, Carlos ACS Catalysis, Vol. 8, Issue 1 https://doi.org/10.1021/acscatal.7b02592	journal	December 2017
Future Paradigm of 3D Printed Ni-Based Metal Organic Framework Catalysts for Dry Methane Reforming: Techno-economic and Environmental Analyses Ong, Jia Ling; Loy, Adrian Chun Minh; Teng, Sin Yong ACS Omega, Vol. 7, Issue 18 https://doi.org/10.1021/acsomega.1c06873	journal	April 2022
Fabrication of Porous Hydrogenation Catalysts by a Selective Laser Sintering 3D Printing Technique Lahtinen, Elmeri; Turunen, Lotta; Hänninen, Mikko M. ACS Omega, Vol. 4, Issue 7 https://doi.org/10.1021/acsomega.9b00711	journal	July 2019
Environmentally Friendly Engineering and Three-Dimensional Printing of TiO ₂ Hierarchical Mesoporous Cellular Architectures Torres Arango, Maria A.; Kwakye-Ackah, Daryl; Agarwal, Sushant ACS Sustainable Chemistry & Engineering, Vol. 5, Issue 11 https://doi.org/10.1021/acssuschemeng.7b02450	journal	October 2017
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Inkjet Printing Assisted Synthesis of Multicomponent Mesoporous Metal Oxides for Ultrafast Catalyst Exploration Liu, Xiaonao; Shen, Yi; Yang, Ruoting Nano Letters, Vol. 12, Issue 11 https://doi.org/10.1021/nl302992q	journal	October 2012
3D printing of versatile reactionware for chemical synthesis Kitson, Philip J.; Glatzel, Stefan; Chen, Wei Nature Protocols, Vol. 11, Issue 5 https://doi.org/10.1038/nprot.2016.041	journal	April 2016
Metal 3D printing technology for functional integration of catalytic system Wei, Qinhong; Li, Hangjie; Liu, Guoguo Nature Communications, Vol. 11, Issue 1 https://doi.org/10.1038/s41467-020-17941-8	journal	August 2020
Highly efficient oxygen evolution reaction via facile bubble transport realized by three-dimensionally stack-printed catalysts Kim, Ye Ji; Lim, Ahyoun; Kim, Jong Min Nature Communications, Vol. 11, Issue 1 https://doi.org/10.1038/s41467-020-18686-0	journal	October 2020
Highly durable, coking and sulfur tolerant, fuel-flexible protonic ceramic fuel cells Duan, Chuancheng; Kee, Robert J.; Zhu, Huayang Nature, Vol. 557, Issue 7704 https://doi.org/10.1038/s41586-018-0082-6	journal	May 2018
High-throughput printing of combinatorial materials from aerosols Zeng, Minxiang; Du, Yipu; Jiang, Qiang Nature, Vol. 617, Issue 7960 https://doi.org/10.1038/s41586-023-05898-9	journal	May 2023
A general approach to 3D-printed single-atom catalysts Xie, Fangxi; Cui, Xiaolin; Zhi, Xing Nature Synthesis, Vol. 2, Issue 2 https://doi.org/10.1038/s44160-022-00193-3	journal	January 2023
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Preparation of monolithic catalysts using 3D printed templates for oxidative coupling of methane Michorczyk, P.; Hędrzak, E.; Węgrzyniak, A. Journal of Materials Chemistry A, Vol. 4, Issue 48 https://doi.org/10.1039/C6TA08629B	journal	January 2016
3D printing in chemical engineering and catalytic technology: structured catalysts, mixers and reactors Parra-Cabrera, Cesar; Achille, Clement; Kuhn, Simon Chemical Society Reviews, Vol. 47, Issue 1 https://doi.org/10.1039/C7CS00631D	journal	January 2018
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3D-printed zeolite monoliths with hierarchical porosity for selective methanol to light olefin reaction Li, Xin; Rezaei, Fateme; Rownaghi, Ali A. Reaction Chemistry & Engineering, Vol. 3, Issue 5 https://doi.org/10.1039/C8RE00095F	journal	January 2018
Conversion of landfill gas to liquid fuels through a TriFTS (tri-reforming and Fischer–Tropsch synthesis) process: a feasibility study Zhao, Xianhui; Naqi, Ahmad; Walker, Devin M. Sustainable Energy & Fuels, Vol. 3, Issue 2 https://doi.org/10.1039/C8SE00344K	journal	January 2019
Rational design and preparation of hierarchical monoliths through 3D printing for syngas methanation Li, Yunhua; Chen, Sijing; Cai, Xiaohu Journal of Materials Chemistry A, Vol. 6, Issue 14 https://doi.org/10.1039/C8TA01597J	journal	January 2018
Monolith catalyst design via 3D printing: a reusable support for modern palladium-catalyzed cross-coupling reactions Alimi, Oyekunle Azeez; Akinnawo, Christianah Aarinola; Meijboom, Reinout New Journal of Chemistry, Vol. 44, Issue 43 https://doi.org/10.1039/D0NJ03651J	journal	January 2020
Zeolites on 3D-printed open metal framework structure: metal migration into zeolite promoted catalytic cracking of endothermic fuels for flight vehicles Hubesch, Roxanne; Mazur, Maciej; Föger, Karl Chemical Communications, Vol. 57, Issue 75 https://doi.org/10.1039/D1CC04246G	journal	January 2021
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Synthesis and application of novel urea–benzoic acid functionalized magnetic nanoparticles for the synthesis of 2,3-disubstituted thiazolidin-4-ones and hexahydroquinolines Fazl, Fazlulhaq; Torabi, Morteza; Yarie, Meysam RSC Advances, Vol. 12, Issue 26 https://doi.org/10.1039/D2RA02205B	journal	January 2022
Tri-reforming of surrogate biogas over Ni/Mg/ceria–zirconia/alumina pellet catalysts Zhao, Xianhui; Ngo, Huong T.; Walker, Devin M. Chemical Engineering Communications, Vol. 205, Issue 8 https://doi.org/10.1080/00986445.2018.1434162	journal	June 2018
3D printed structures for optimized carbon capture technology in packed bed columns Bolton, Stephen; Kasturi, Abishek; Palko, Scott Separation Science and Technology, Vol. 54, Issue 13 https://doi.org/10.1080/01496395.2019.1622566	journal	February 2019
Materials Properties of Printable Edible Inks and Printing Parameters Optimization during 3D Printing: a review Feng, Chunyan; Zhang, Min; Bhandari, Bhesh Critical Reviews in Food Science and Nutrition, Vol. 59, Issue 19 https://doi.org/10.1080/10408398.2018.1481823	journal	June 2018
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Toward digitally controlled catalyst architectures: Hierarchical nanoporous gold via 3D printing Zhu, Cheng; Qi, Zhen; Beck, Victor A. Science Advances, Vol. 4, Issue 8 https://doi.org/10.1126/sciadv.aas9459	journal	August 2018
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Ceramic-Based 3D Printed Supports for Photocatalytic Treatment of Wastewater Hernández-Afonso, Lorena; Fernández-González, Ricardo; Esparza, Pedro Journal of Chemistry, Vol. 2017 https://doi.org/10.1155/2017/7602985	journal	January 2017
Stereolithography 3D-Printed Catalytically Active Devices in Organic Synthesis Rossi, Sergio; Puglisi, Alessandra; Raimondi, Laura Maria Catalysts, Vol. 10, Issue 1 https://doi.org/10.3390/catal10010109	journal	January 2020
High-Complexity WO3-Based Catalyst with Multi-Catalytic Species via 3D Printing Wang, Xiaofeng; Guo, Wei; Abu-Reziq, Raed Catalysts, Vol. 10, Issue 8 https://doi.org/10.3390/catal10080840	journal	July 2020
Multi-Scale Studies of 3D Printed Mn–Na–W/SiO2 Catalyst for Oxidative Coupling of Methane Karsten, Tim; Middelkoop, Vesna; Matras, Dorota Catalysts, Vol. 11, Issue 3 https://doi.org/10.3390/catal11030290	journal	February 2021
Catalytic Materials by 3D Printing: A Mini Review Chen, Lina; Zhou, Shiqiang; Li, Mengrui Catalysts, Vol. 12, Issue 10 https://doi.org/10.3390/catal12101081	journal	September 2022
Wastewater Treatment by Advanced Oxidation Process and Their Worldwide Research Trends Garrido-Cardenas, José Antonio; Esteban-García, Belén; Agüera, Ana International Journal of Environmental Research and Public Health, Vol. 17, Issue 1 https://doi.org/10.3390/ijerph17010170	journal	December 2019
3D Printing in Heterogeneous Catalysis—The State of the Art Bogdan, Elżbieta; Michorczyk, Piotr Materials, Vol. 13, Issue 20 https://doi.org/10.3390/ma13204534	journal	October 2020
Progress and Recent Strategies in the Synthesis and Catalytic Applications of Perovskites Based on Lanthanum and Aluminum Muñoz, Helir Joseph; Korili, Sophia A.; Gil, Antonio Materials, Vol. 15, Issue 9 https://doi.org/10.3390/ma15093288	journal	May 2022
A Review on New 3-D Printed Materials’ Geometries for Catalysis and Adsorption: Paradigms from Reforming Reactions and CO2 Capture Soliman, Ahmad; AlAmoodi, Nahla; Karanikolos, Georgios N. Nanomaterials, Vol. 10, Issue 11 https://doi.org/10.3390/nano10112198	journal	November 2020

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