Enhanced CO2 methanation with ceramic 3D printed catalyst bed reactor

• An innovative approach has been developed for fabricating CO 2 methanation reactors. • 3D printed stainless steel and alumina micro-channel reactors are introduced. • Performance enhancement is achieved by 3D structuration of reactor design. • 3D printing opens new pathways for production of advanced catalytic devices. 3D printing is revolutionizing manufacturing, particularly in fields where complex shapes offer significant advantages, such as catalysis. This study demonstrates the potential of the ceramic-based additive manufacturing for producing catalytic beds for CO 2 methanation. In particular, it demonstrates the effectiveness of alumina catalytic beds with flat channels, fabricated via stereolithography, within the temperature range of 260 – 340 °C. 3D-printed beds show a 20 % performance increase compared to stainless-steel catalytic supports made through conventional milling and selective laser sintering. This research introduces a novel approach to produce catalytic materials, combining the advantages of additive manufacturing with the selection of materials that have optimal catalytic properties. Additionally, the 3D structuring of channels with a herringbone pattern further improves CO 2 conversion by 15 % at 300 °C, due to an increase of the functional area and enhanced flow distribution along the channel. Overall, this study paves the way for further advancements by incorporating advanced features into catalytic beds employing ceramic 3D printing technologies.