3D printing of metal-based materials for renewable energy applications

Mooraj, Shahryar; Zhang, Qi; Zhu, Cheng; Ren, Jie; Peng, Siyuan; Liu, Liang; Zhang, Shengbiao; Feng, Shuai; Kong, Fanyue; Liu, Yanfang; Duoss, Eric B.; Baker, Sarah E.; Chen, Wen

doi:10.1007/s12274-020-3230-x

Cited by 35 publications

(14 citation statements)

References 212 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Topology optimization has immense potential to optimize the structure of porous electrodes for electrochemical applications. With the rise of high-resolution additive-manufacturing techniques, , the design space for porous electrodes has been revolutionized; multiple recent studies have demonstrated the capacity to 3-D-print porous electrodes for electrochemical applications, ,− with some possessing improved mass-transport properties compared to conventional porous electrodes. ,,,,, Topology optimization interfaces well with these advanced manufacturing techniques, , and the ability to manufacture complex porous electrodes motivates the development of topology optimized electrodes for a variety of electrochemical applications.…”

Section: Future Directionsmentioning

confidence: 99%

Continuum Modeling of Porous Electrodes for Electrochemical Synthesis

et al. 2022

View full text Add to dashboard Cite

Electrochemical synthesis possesses substantial promise to utilize renewable energy sources to power the conversion of abundant feedstocks to value-added commodity chemicals and fuels. Of the potential system architectures for these processes, only systems employing 3-D structured porous electrodes have the capacity to achieve the high rates of conversion necessary for industrial scale. However, the phenomena and environments in these systems are not well understood and are challenging to probe experimentally. Fortunately, continuum modeling is well-suited to rationalize the observed behavior in electrochemical synthesis, as well as to ultimately provide recommendations for guiding the design of next-generation devices and components. In this review, we begin by presenting an historical review of modeling of porous electrode systems, with the aim of showing how past knowledge of macroscale modeling can contribute to the rising challenge of electrochemical synthesis. We then present a detailed overview of the governing physics and assumptions required to simulate porous electrode systems for electrochemical synthesis. Leveraging the developed understanding of porous-electrode theory, we survey and discuss the present literature reports on simulating multiscale phenomena in porous electrodes in order to demonstrate their relevance to understanding and improving the performance of devices for electrochemical synthesis. Lastly, we provide our perspectives regarding future directions in the development of models that can most accurately describe and predict the performance of such devices and discuss the best potential applications of future models.

show abstract

Section: Future Directionsmentioning

confidence: 99%

Continuum Modeling of Porous Electrodes for Electrochemical Synthesis

et al. 2022

View full text Add to dashboard Cite

show abstract

“…At the present time, the use of additive manufacturing for the production of geometric supports with tailored properties is a hot research topic, which is stimulating a strong research activity in the field. Detailed reviews are available, providing general information on the stages of the 3D printing process, 3D printing methods, and applications in the field of heterogeneous catalysis (Hurt et al, 2017;Soliman et al, 2020;Laguna et al, 2021;Lawson et al, 2021;Mooraj et al, 2021).…”

Section: Additive Manufacturing Of Geometric Supportsmentioning

confidence: 99%

Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

et al. 2022

View full text Add to dashboard Cite

Structured catalysts are strong candidates for the intensification of non-adiabatic gas-solid catalytic processes thanks to their superior heat and mass transfer properties combined with low pressure drops. In the past two decades, different types of substrates have been proposed, including honeycomb monoliths, open-cell foams and, more recently, periodic open cellular structures produced by additive manufacturing methods. Among others, thermally conductive metallic cellular substrates have been extensively tested in heat-transfer limited exo- or endo-thermic processes in tubular reactors, demonstrating significant potential for process intensification. The catalytic activation of these geometries is critical: on one hand, these structures can be washcoated with a thin layer of catalytic active phase, but the resulting catalyst inventory is limited. More recently, an alternative approach has been proposed, which relies on packing the cavities of the metallic matrix with catalyst pellets. In this paper, an up-to-date overview of the aforementioned topics will be provided. After a brief introduction concerning the concept of structured catalysts based on highly conductive supports, specific attention will be devoted to the most recent advances in their manufacturing and in their catalytic activation. Finally, the application to the methane steam reforming process will be presented as a relevant case study of process intensification. The results from a comparison of three different reactor layouts (i.e. conventional packed bed, washcoated copper foams and packed copper foams) will highlight the benefits for the overall reformer performance resulting from the adoption of highly conductive structured internals.

show abstract

“…39,40) The vacuum sintering method, only fabricates open-pored porous materials, uses preformed metal powder and metal fibers to form a blank, and then sintering in vacuum furnace at high temperature. In addition to the traditional technologies mentioned above, new technologies such as space support manufacturing, 41,42) powder injection molding [43][44][45] and 3D printing technology [46][47][48] have been developed in recent years. It is worth mentioning that stainless steel powder and stainless steel wire mesh composite porous plates (SPSWMCPs) could be prepared by the combination of metal powder and metal wire mesh.…”

Section: Preparation Microstructure and Impact Properties Of A Novel ...mentioning

confidence: 99%