Catalyst coated 3D-printed static mixers for flow reactors.
CSIRO scientists working at FloWorks have developed catalyst coated, metal 3D-printed static mixers for use in continuous flow reactors. Static mixers cause additional churn and mixing in a flow reactor, improving the efficiency of a continuous flow manufacturing process.
![Catalytic static mixer inserted in reactor tube.](https://i0.wp.com/research.csiro.au/floworks/wp-content/uploads/sites/110/2017/01/CSM-in-tube.png?resize=300%2C192&ssl=1)
A 3D-printed catalytic static mixer inserted into a reactor tube.
The work, published recently in Reaction Chemistry & Engineering1 (free access until end of 2017), brought together a multi-disciplinary team to design (CFD), 3D-print in metal, and coat in catalysts static mixers for insertion into stainless steel tubing used in standard flow reactors.
![Static mixer designs.](https://i0.wp.com/research.csiro.au/floworks/wp-content/uploads/sites/110/2017/01/CSM-designs.png?resize=300%2C134&ssl=1)
Different static mixer designs.
The base substrate can be printed in Ti-alloy, CoCr-alloy, Al-alloy, 316 SS, and other materials, using our metal 3D-printers.
The catalysts were then applied using either electrodeposition or metal cold-spray techniques, and evaluated in continuous flow hydrogenations. This initial work successfully coated Ni, Pt, Pd, Cu, and Au onto the bare base substrate.
![Nickel coldspray coating.](https://i0.wp.com/research.csiro.au/floworks/wp-content/uploads/sites/110/2017/01/CSM-Ni-coldspray.png?resize=300%2C204&ssl=1)
Static mixer after nickel cold spray coating.
![Copper electrodeposition.](https://i0.wp.com/research.csiro.au/floworks/wp-content/uploads/sites/110/2017/01/CSM-Cu.png?resize=300%2C92&ssl=1)
Electrodeposition of copper onto static mixer.
This approach allows FloWorks to custom design a mixer specifically for an end-user’s manufacturing needs, and scale-up and automate the production of the static mixers.
[1] Continuous flow hydrogenations using novel catalytic static mixers inside a tubular reactor, A. Avril, C. Hornung, A. J. Urban, D. Fraser, M. Horne, J.-P. Veder, J. Tsanaktsidis, T. Rodopoulos, C. Henry, and D. Gunasegaram, React. Chem. Eng., 2016, doi:10.1039/C6RE00188B.