Auto-Pressurized Multi-Stage Tesla-Valve Type Microreactors in Carbon Monoliths Obtained Through 3D Printing: Impact of Design on Fluid Dynamics and Catalytic Activity

The present research exploits an innovative methodology for producing auto-pressurized carbon microreactors with a precise and controlled structure analyzing the influence of their design on the fluid dynamics and their catalytic performance. Carbon monoliths with Tesla-valve shape channels (Tesla, T, and modified Tesla, Tm) are synthesized through the combination of 3D printing and sol–gel process and further probed as Ni/CeO2 supports on CO2 methanation. The experimental results and mathematical modeling corroborated the improved performance obtained through the complex design compared to a conventional one. In addition to chaotic fluid flow induced by the deviation in flow direction, which improves the reagents-active phase interaction, local pressure increases due to convergence of flows may enhance the Sabatier reaction according to Le Châtelier%27s principle. Conversely to straight channels, T and Tm are not affected by flow rate and presented chemical control. Tesla-valve with curved angle (Tm) improved the mass transfer, achieving higher conversion and ≈30%25 reaction rate increase regarding right angle (T). Thus, this auto-pressurized multi-stage Tesla-valve monolith opens the gate to design specific and advanced functional materials for multitude chemical reactions where not only the reactant-active phase contact can be maximized but also the reaction conditions can be controlled to maximize the reaction kinetics.

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