Catalytic Applications of 3D Printed Zeolite Monoliths
This study explores the superior customisation, performance, energy efficiency, design flexibility, and sustainability of 3D printed zeolite fabrications compared to traditional catalyst shaping methods. Utilising a modified desktop 3D printer and PrusaSlicer software, the research demonstrates how...
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| Format: | Dissertation |
| Language: | English |
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ProQuest Dissertations & Theses
01-01-2024
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| Online Access: | Get full text |
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| Summary: | This study explores the superior customisation, performance, energy efficiency, design flexibility, and sustainability of 3D printed zeolite fabrications compared to traditional catalyst shaping methods. Utilising a modified desktop 3D printer and PrusaSlicer software, the research demonstrates how complex 3D models can be produced effectively without extensive expertise in 3D design, making advanced catalyst fabrication accessible to a broader range of researchers.The investigation focused on various factors affecting the structural integrity and performance of zeolite monoliths. By examining different building plate materials, binder contents, and structural designs, the study identified that maintaining a binder balance of 30 wt.% is critical for achieving optimal mechanical stability and wood building plate enhance the evaporation rates. The employment of a hybrid drying technique, which combines microwave and conventional drying methods, successfully maintaining the quality of the monoliths.Further analysis highlighted a notable correlation between slurry concentration and catalyst loading on cordierite substrates for stove applications, achieving a peak loading of 19.6 wt.%. This phase of the research innovated by incorporating active materials directly within the printing paste, which facilitated an increase in catalyst loading to over 50 wt.%, significantly enhancing the potential for stove catalytic activity.The fine-tuning attempts extended to the production of light olefins, with the study assessing the impacts of binder composition, temperature, Si/Al ratio, and monolith infill designs on catalyst performance. It was found that medium infill densities, specifically 50%, provided the best balance between conversion rates and product selectivity. Computational Fluid Dynamics (CFD) simulations further elucidated how variations in infill density affect fluid flow and pressure drop within the monoliths, directly influencing operational efficiency and catalytic effectiveness. Notably, monoliths with interconnected channel designs demonstrated superior performance in n-heptane conversion and ethene and propene selectivity compared to those with straight channels, due to their enhanced gas velocity and optimised residence time.The study also explored the economic and environmental benefits of replacing traditional noble metals in stove catalytic combustors with lower-cost metals like iron and copper for use in stove combustion appliances. The Fe-ZSM-5 monoliths (FeD) dramatically reduced carbon monoxide emissions by 72.3% from dry beech and 51.9% from wet beech. Similarly, the Cu-ZSM-5 monoliths (CuD) were shown to reduce polycyclic aromatic hydrocarbon (PAH) emissions significantly. Moreover, 3D printed clay monoliths (InD filter) were proven to reduce total particulate matter emissions (PMTOT) by 14.1%, PM1 emissions by 10.4%, and PM1-PM2.5 emissions by 11.9%, confirming their potential as effective and environmentally sustainable alternatives. These monoliths also offer the practical advantage of being easily cleanable and regenerable. |
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| ISBN: | 9798342139441 |