Geometric Structure-Dependent Catalyst Performance in CH4 Reforming Using Ni-Based Catalysts

The specific surface area, porosity, and mechanical properties of a catalyst are critical factors that significantly influence its performance. However, conventional preparation techniques are incapable of optimizing these properties simultaneously. Here, we present the performance of three kinds of catalysts with different geometric structures. Our findings indicated that the porosity, specific surface area, and mechanical properties of the 3D-printed catalysts achieved an optimal balance, exhibiting enhanced catalytic efficiency and mechanical integrity compared to commercial catalysts. Furthermore, the excellent ductility of the metal catalyst supports effectively prevented catalyst pulverization caused by carbon deposition and the thermal expansion of the supports. These results demonstrate that 3D printing technology can open up novel avenues for catalyst preparation, especially for metal-supported catalysts. The potential of metal additive manufacturing in chemical engineering is substantial, promising transformative advancements in the design and fabrication of catalytic converters and reactors.