Graphene-based nanostructures as catalysts for wet peroxide oxidation treatments: From nanopowders to 3D printed porous monoliths

3D printed monoliths: From powder to an efficient catalyst for antibiotic degradation

To improve the effectiveness and durability of wastewater treatment technologies, researchers are showing a growing interest in 3D printing technology. This technology has attracted significant interest owing to its ability to fabricate challenging complex geometries using different material compositions. This manuscript is focused on the development of 3D monoliths from noncommercial filaments, i.e., a powder blend of iron oxide and polylactic acid (PLA) at 15 wt% of the former. Different monolith designs have been prepared to improve the fluid dynamics of the process, so a simple cylinder (15-Fe3O4@PLA) and a cylinder with double the length and an internal mesh (15-Fe3O4@PLA-DM) were used. These monoliths were characterized by Scanning electron microscopy (SEM), Differential scanning calorimetry (DSC) and Mössbauer spectroscopy, then used for water-based ofloxacin degradation in a continuous down-up flow configuration. Additionally, computational fluid dynamics simulations were performed to estimate the degradation rate constants and analyze the distribution of fluid velocity and pollutant concentration along the 15-Fe3O4@PLA-reactor. The oxidant dose was also optimized to develop the highest degradation rate. The degradation of the target pollutant for those monoliths was 55 and 82 % under optimized conditions. In addition, the 15-Fe3O4@PLA-DM monolith was operated for long term experiments, keeping the degradation performance at a good 67 % for up to 120 h. Finally a fixed-bed reactor was mounted with printed pellets of the mixture (15:85), Fe3O4:PLA, after being ground in a range of 125-200 μm. Under this setup configuration, we observed the total degradation of ofloxacin. 3D printing technology is cheap, reproducible and time saving in the development of supported catalysts in comparison with conventional deposition techniques. Moreover, the leaching of active sites on streams was largely diminished. In fact under continuous operation the leached Fe concentration is below 0.1 ppm, corroborating the good adhesion of the catalyst in the PLA support.

Metal 3D printing technology for functional integration of catalytic system

Mechanical properties and geometries of printed products have been extensively studied in metal 3D printing. However, chemical properties and catalytic functions, introduced by metal 3D printing itself, are rarely mentioned. Here we show that metal 3D printing products themselves can simultaneously serve as chemical reactors and catalysts (denoted as self-catalytic reactor or SCR) for direct conversion of C1 molecules (including CO, CO₂ and CH₄) into high value-added chemicals. The Fe-SCR and Co-SCR successfully catalyze synthesis of liquid fuel from Fischer-Tropsch synthesis and CO₂ hydrogenation; the Ni-SCR efficiently produces syngas (CO/H₂) by CO₂ reforming of CH₄. Further, the Co-SCR geometrical studies indicate that metal 3D printing itself can establish multiple control functions to tune the catalytic product distribution. The present work provides a simple and low-cost manufacturing method to realize functional integration of catalyst and reactor, and will facilitate the developments of chemical synthesis and 3D printing technology.

Metal 3D printing is a very promising technology to revolutionize catalytic systems. Here the authors show that metal 3D printing products themselves can simultaneously serve as chemical reactors and catalysts for conversion of C1 molecules into high value-added chemicals.

Simulation and Optimization of the CWPO Process by Combination of Aspen Plus and 6-Factor Doehlert Matrix: Towards Autothermal Operation

This work aims to present an industrial perspective on Catalytic Wet Peroxide Oxidation (CWPO) technology. Herein, process simulation and experimental design have been coupled to study the optimal process conditions to ensure high-performance oxidation, minimum H2O2 consumption and maximum energetic efficiency in an industrial scale CWPO unit. The CWPO of phenol in the presence of carbon black catalysts was studied as a model process in the Aspen Plus® v11 simulator. The kinetic model implemented, based on 30 kinetic equations with 11 organic compounds and H2O2 involvement, was valid to describe the complex reaction network and to reproduce the experimental results. The computer experiments were designed on a six-factor Doehlert Matrix in order to describe the influence of the operating conditions (i.e., the different process temperatures, inlet chemical oxygen demands, doses of H2O2 and space time) on each selected output response (conversion, efficiency of H2O2 consumption and energetic efficiency) by a quadratic model. The optimization of the WPO performance by a multi-criteria function highlighted the inlet chemical oxygen demand as the most influential operating condition. It needed to have values between 9.5 and 24 g L−1 for autothermal operation to be sustained under mild operating conditions (reaction temperature: 93–130 °C and pressure: 1–4 atm) and with a stoichiometric dose of H2O2.

Activated Carbon in the Third Dimension-3D Printing of a Tuned Porous Carbon

A method for obtaining hierarchically structured porous carbons, employing 3D printing to control the structure down to the lower µm scale, is presented. To successfully 3D print a polymer precursor and transfer it to a highly stable and structurally conformal carbon material, stereolithography 3D printing and photoinduced copolymerization of pentaerythritol tetraacrylate and divinylbenzene are employed. Mechanically stable structures result and a resolution of ≈15 µm is demonstrated. This approach can be combined with liquid porogen templating to control the amount and size (up to ≈100 nm) of transport pores in the final carbonaceous material. Additional CO2 activation enables high surface area materials (up to 2200 m2 g-1) that show the 3D printing controlled µm structure and nm sized transport pores. This unique flexibility holds promise for the identification of optimal carbonaceous structures for energy application, catalysis, and adsorption.