(481c) 3D Printed Fixed Bed Catalytic Monolith for Continuous Chemistry

Various support structures (metal, ceramic, polymer) are used to anchor or enhance heterogeneous catalysts. Metal and ceramic monolith support structures are typically extruded. Extruded monoliths contain regular, parallel channels enabling high throughput because of the low pressure drop accompanying high flow rate. However, extruded channels have low surface-area-to-volume ratios resulting in low contact between the reagent and catalyst. Three-dimensional printing (3dP) can be used to overcome disadvantages of extruded monoliths while also preventing channeling due to a fixed bed. 3dP enables precise control over all design parameters of the monolith. The polymer, reactor design, and bed geometry can be easily tuned to match different reaction systems based on reaction kinetics and desired throughput. Additionally, 3dP allows for reactor design based on system constraints (e.g. design a less dense bed geometry to minimize backpressure for a peristaltic pump). We have implemented a rational design approach to 3dP monoliths (made from commercially available filament) that continuously catalyze cross-coupling reactions. This system is reproducible, versatile, and scalable.