Innovative Production of 3D-Printed Ceramic Monolithic Catalysts for Oxidation of VOCs by Using Fused Filament Fabrication

In this work, ceramic monolithic catalyst carriers based on zirconium dioxide (ZrO2) were produced using fused filament fabrication (FFF). The active catalyst components were deposited on the resulting carriers using the wet impregnation method. The activity of the prepared monolithic catalysts was evaluated by catalytic oxidation of a mixture of aromatic volatile organic compounds: benzene, toluene, ethylbenzene, and o-xylene (BTEX). The efficiency of the prepared monolithic catalysts was investigated as a function of the geometry of the monolithic carrier (ZDP, Z, and M) and the chemical composition of the catalytically active component (MnFeOx, MnCuOx, and MnNiOx) during the catalytic oxidation of BTEX compounds. The mechanical stability of the catalyst layer and the dimensional stability of the 3D-printed monolithic catalyst carriers were investigated prior to the kinetic measurements. In addition, thorough characterization of the commercial ZrO2-based filament was carried out. The results of the efficiency of the prepared monolithic catalysts for the catalytic oxidation of BTEX showed that the 3D-printed model M, which contained MnFeOx as the catalytically active component, was the most successful catalyst for the oxidation of BTEX compounds. The mentioned catalyst enables the catalytic oxidation of all components of the BTEX mixture (>99% efficiency) at a temperature of 177 °C.