Auto‐Pressurized Multi‐Stage Tesla‐Valve Type Microreactors in Carbon Monoliths Obtained Through 3D Printing: Impact of Design on Fluid Dynamics and Catalytic Activity

• Published in: Advanced functional materials 2024-10, Vol.34 (40), p.n/a
• Main Authors: Parra‐Marfil, Adriana, Aguilar‐Madera, Carlos Gilberto, Pérez‐Cadenas, Agustín Francisco, Carrasco‐Marín, Francisco, Gutiérrez‐Reina, Saúl Omar, Bueno‐López, Agustín, Ocampo‐Pérez, Raúl, Bailón‐García, Esther
• Format: Article
• Language: English
• Subjects: 3-D printers; additive manufacturing; auto‐pressurized monolithic catalyst; Carbon; Catalytic activity; Cerium oxides; Chemical reactions; CO2 capitalization; CO2 methanation reaction; Contact angle; Control valves; Dynamic structural analysis; Fluid dynamics; Fluid flow; Functional materials; Impact analysis; Mass transfer; mathematical modeling; Methanation; Microreactors; Monolithic materials; Reaction kinetics; Reagents; Sabatier reaction; Sol-gel processes; Straight channels; Tesla‐valve configuration; Three dimensional printing
• ISSN: 1616-301X; 1616-3028
• DOI: 10.1002/adfm.202403659

The present research exploits an innovative methodology for producing auto‐pressurized carbon microreactors with a precise and controlled structure analyzing the influence of their design on the fluid dynamics and their catalytic performance. Carbon monoliths with Tesla‐valve shape channels (Tesla, T, and modified Tesla, Tm) are synthesized through the combination of 3D printing and sol–gel process and further probed as Ni/CeO2 supports on CO2 methanation. The experimental results and mathematical modeling corroborated the improved performance obtained through the complex design compared to a conventional one. In addition to chaotic fluid flow induced by the deviation in flow direction, which improves the reagents‐active phase interaction, local pressure increases due to convergence of flows may enhance the Sabatier reaction according to Le Châtelier's principle. Conversely to straight channels, T and Tm are not affected by flow rate and presented chemical control. Tesla‐valve with curved angle (Tm) improved the mass transfer, achieving higher conversion and ≈30% reaction rate increase regarding right angle (T). Thus, this auto‐pressurized multi‐stage Tesla‐valve monolith opens the gate to design specific and advanced functional materials for multitude chemical reactions where not only the reactant‐active phase contact can be maximized but also the reaction conditions can be controlled to maximize the reaction kinetics. This research pioneers the synthesis of monolithic catalysts with precisely controlled channel designs using sol–gel polymerization and 3D printing. The study introduces auto‐pressurized multi‐stage Tesla‐valve microreactors, optimizing fluid dynamics and reaction kinetics. Carbon monoliths with Tesla‐like channels (Tesla, T, and modified Tesla, Tm) outperform conventional designs in CO2 methanation, showcasing enhanced mass transfer and consistent performance across flow rates. This innovative approach unlocks possibilities for tailored functional materials in diverse chemical reactions.