(459e) A 3D-Printed Gyroid Ni/Al2O3 Catalyst for CO2 Methanation

The utilization of 3D-printing in catalyst production for CO₂ methanation has emerged as a response to the challenges posed by the highly exothermic reaction and high gas space velocity, conditions that necessitate enhanced heat and mass transfer while maintaining optimal catalytic performance¹. In this work, we developed a new CO₂ methanation catalyst comprising a Ni/Al₂O₃ powder-coated 3D-printed aluminum alloy of gyroid configuration. The metallic aluminum alloy (AlMgSi) was 3D-printed (3DAL) using selective laser melting (SLM), and Ni/Al₂O₃ powder was coated on it by washcoating. Microscopy and tomography techniques were employed to examine the morphological characteristics of the catalyst and to analyze internal topology, and hydrogen temperature-programmed reduction (H₂-TPR) and chemisorption provided insights into the reduction sites and active metal phase. The catalytic performance was assessed through CO₂ methanation experiments conducted at various temperatures ranging from 250 °C to 500 °C, using a CO₂:H₂:He gas mixture (1:4:5). The 3D-printed Ni/Al₂O₃-3DAL catalyst exhibited high CH₄ selectivity (97.7%) and CO₂ conversion (77.6%) at 400 °C, which can be attributed to the reduced tendency of sintering and the effective heat transfer owing to the metallic support. The 3D-printed gyroid-sheet metallic support provided a higher surface area-to-volume ratio, enabling higher catalyst loading per unit volume and improved reactants contact with the active catalyst phase yielding enhanced catalytic performance compared to powder. It also offers potential for enhanced thermal energy management and mechanical strength compared to conventional beads and pellets.

References:

1. Jivrakh KB, Kuppireddy S, Dumée LF, et al. A critical review on 3D-printed adsorbents, membranes, and catalysts for carbon dioxide capture, separation, and conversion. J Clean Prod. 2024;472:143522. doi:10.1016/J.JCLEPRO.2024.143522