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<p>3D-printed catalysts with open-celled structures can significantly reduce mass and heat transfer resistance compared with traditional pellet counterparts. However, current 3D printing techniques typically achieve only about 70 wt% zeolite loading. While higher loading is desirable to improve catalyst performance, it also increases slurry viscosity, leading to printing challenges such as nozzle clogging and extrusion difficulties. In this work, we present a new direct ink writing (DIW) slurry formulation that increases the zeolite loading limit to 90.5 wt% while maintaining good printability. We found that incorporating a nonionic dispersant, such as hydroxypropyl methylcellulose (HPMC), is more effective in preventing particle aggregation and sedimentation than using an anionic dispersant like carboxymethyl cellulose (CMC). Optimized preprocessing parameters (slurry aging, printing speed, extrusion rate, and nozzle size) along with post-processing conditions (calcination temperature) are reported to yield high-quality 3D printed zeolite catalyst monoliths. Adequate calcination at 600 °C results in the highest accessible specific surface area (SSA) and excellent structural integrity, sustaining compressive strength up to 1.77 MPa. The mechanical strength is over 200% higher than that of existing 3D-printed zeolite catalysts.</p>

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High-loading 3D-printed open-cell zeolite catalysts with enhanced structural integrity

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年6月3日

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  • Ya Tang,
  • Sanjita Wasti,
  • Katie Copenhaver,
  • Michelle K. Kidder,
  • Kaustubh Mungale,
  • Cait M. Clarkson,
  • Halil Tekinalp,
  • Soydan Ozcan,
  • Xianhui Zhao,
  • Yan Li

摘要

3D-printed catalysts with open-celled structures can significantly reduce mass and heat transfer resistance compared with traditional pellet counterparts. However, current 3D printing techniques typically achieve only about 70 wt% zeolite loading. While higher loading is desirable to improve catalyst performance, it also increases slurry viscosity, leading to printing challenges such as nozzle clogging and extrusion difficulties. In this work, we present a new direct ink writing (DIW) slurry formulation that increases the zeolite loading limit to 90.5 wt% while maintaining good printability. We found that incorporating a nonionic dispersant, such as hydroxypropyl methylcellulose (HPMC), is more effective in preventing particle aggregation and sedimentation than using an anionic dispersant like carboxymethyl cellulose (CMC). Optimized preprocessing parameters (slurry aging, printing speed, extrusion rate, and nozzle size) along with post-processing conditions (calcination temperature) are reported to yield high-quality 3D printed zeolite catalyst monoliths. Adequate calcination at 600 °C results in the highest accessible specific surface area (SSA) and excellent structural integrity, sustaining compressive strength up to 1.77 MPa. The mechanical strength is over 200% higher than that of existing 3D-printed zeolite catalysts.