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Catalysis and 3D Printing Fields Converge to Transform Carbon Dioxide Decarbonization

Researchers from Khalifa University’s Center for Catalysis and Separation (CeCaS) and Advanced Digital & Additive Manufacturing (ADAM) Group are merging the fields of catalysis and 3D printing to develop groundbreaking technologies for capturing and converting carbon dioxide (CO2), a critical step in addressing the global challenge of decarbonization. This is part of the SynERGON joint initiative in CeCaS, which aims to break the silos and create more areas of collaboration among traditional and contemporary fields of research towards creation of innovative solutions.

in Separation and Purification Technology, a top 10% journal, the paper titled ‘Zeolite-coated 3D-printed gyroid scaffolds for carbon dioxide adsorption’ ÐÇ¿Õ´«Ã½ how 3D printing can be used to create structured adsorbents which can improve performance in sustainable CO2 capture applications. The synergy between catalysis and 3D printing has allowed the team to overcome long standing limitations and create innovative solutions for sustainable carbon management. 

The research team includes Professor Kyriaki Polychronopoulou, Director, CeCaS, and Professor, Mechanical Engineering, Dr. Georgios Karanikolos, Associate Professor, Chemical Engineering, University of Patras and external collaborator, CeCaS, Dr. Nahla Al Amoodi, Theme 2 leader, Kedar Jivrakh, PhD student from CeCas, and Professor Rashid Abu Al-Rub, Director, ADAM, and Professor, Mechanical Engineering.

The team has identified that the main challenge in 3D printed adsorbents is low mechanical strength which needs to be improved and we are currently working on it by utilizing adsorbents grown in-situ on 3D-printed metal supports. 

3D printing allows the precise fabrication of complex, high-surface-area structures, significantly improving the efficiency of CO2 capture and conversion. By combining the strengths of catalysis and additive manufacturing, the team is creating customized adsorbents and catalysts that outperform conventional materials.

For CO2 capture, the researchers utilized 3D printing techniques like selective laser melting (SLM), stereolithography (SLA), and digital light processing (DLP) to fabricate structured zeolite-based adsorbents with optimized geometries, such as gyroid sheets.

Additionally, the team explored 3D printing of metal supports coated with catalysts for converting captured CO2 into useful fuels or chemicals. The 3D-printed metallic supports facilitated efficient heat dissipation, leading to enhanced catalytic stability and activity.

Alisha Roy
Science Writer
10 July 2024