Development of structured ceramic catalyst supports using robocasting technology

• Grant number: 24/13525-9
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• Start date: September 01, 2024
• End date: August 31, 2025
• Field of knowledge: Engineering - Chemical Engineering - Chemical Technology
• Principal Investigator: Bruno Ramos
• Grantee: Carolina Mendes Furlan Ferreira
• Host Institution: Centro Universitário FEI (UNIFEI). Campus de São Bernardo do Campo. São Bernardo do Campo , SP, Brazil
• Associated research grant: 23/14214-4 - Development of structured catalysts for the photocatalytic synthesis of ammonia, AP.PFPMCG.R

Abstract

The demand for more efficient and specific catalysts has grown significantly, driven by industrial applications that seek more sustainable and economical processes. Ceramic supports, essential for the stabilisation of catalysts and the enhancement of catalytic efficiency, are distinguished by their high surface area, thermal and chemical stability. However, manufacturing supports with complex geometries and controlled porosities poses a significant challenge using traditional methods. The robocasting method, selected for this study, allows for the construction of three-dimensional ceramic structures layer by layer, with micrometric precision. This technique offers high flexibility in controlling the internal architecture of the supports, enabling the optimisation of properties such as porosity, pore distribution, and specific surface area. Such characteristics are expected to result in objects with well-defined geometry, facilitating the refinement of heterogeneous catalytic processes and reactor development. During the project's development, different compositions of ceramic pastes, printing parameters, and post-processing treatments will be explored to achieve the desired characteristics of the final products. The evaluation of the supports will be conducted using techniques such as scanning electron microscopy (SEM), mercury porosimetry, and nitrogen adsorption spectroscopy to characterise morphology, porosity, and surface area, respectively. This project is expected to bring significant advancements in the field of catalysis, offering a viable route for the production of ceramic supports with customised properties for specific applications. Additionally, the implementation of the robocasting technique in the manufacture of catalytic materials may contribute to the optimisation of industrial chemical processes, steering efforts towards sustainability and energy efficiency.