| Abstract Scope |
Industrial heterogeneous packed-bed reactors are often limited by poor heat transfer, non-uniform flow distribution, high pressure drop, and low mechanical durability of the pelletized catalysts. Additive manufacturing (AM) of monolithic catalysts offers a potential solution to these issues, particularly for highly exothermic and endothermic reactions. In this presentation, new concepts in reactor design enabled by AM will be explored:
simultaneous AM of the pressure retaining the barrier and monolithic catalyst support; AM of triply periodic minimal surface structures and the potential benefits of a sheet gyroid reactor configuration; multi-scale control between the catalyst support geometry and its microstructural properties; incorporation of the active metal precursor in AM process to eliminate the catalyst infiltration step; use of topology optimisation in monolithic catalyst support design. An example application in high-test hydrogen peroxide decomposition will be presented along with prospects for important industrial reactions like steam-methane reforming, ammonia synthesis, and methanol synthesis. |