3D printed catalytic reactors for aerobic selective oxidation of benzyl alcohol into benzaldehyde in continuous multiphase flow

In this work, novel, patterned monolithic reactors were devised to explore more efficient routes for reactant conversion in order investigate their potential replace the packed bed and batch conventionally employed chemical industries. Well-defined bimetallic formulations developed substitute platinum group metals critical raw materials such as palladium cobalt, at least part, by less active, but sustainable cost-effective earth-abundant iron. FePd FeCo based monoliths 3D printed stacked a continuous flow tubular reactor testing selective oxidation of benzyl alcohol (BA) into benzaldehyde (BZ) under mild conditions (80–100 °C atmospheric pressure). The novel evaluated against current state-of-the-art technologies, conventional reactors. FeCo- FePd-Al2O3-supported catalyst beds showed higher TOF than counterparts same operating conditions, revealing impact design on both regular geometry composition. What is particular interest catalytic measurements shown that combined stacking two reactor, Al2O3-supported Fe GO-supported catalysts, can significantly improve performance with an increase up 90% comparison analogues. Mathematical modelling was used obtain additional insights physical processes governing rate BA conversion. It found due regime inside microchannels, axial dispersion model appropriate, which allowed mapping concentration profiles reactants products within respective monolith geometries.