3D-printing of metallic honeycomb monoliths as a doorway to a new generation of catalytic devices: the Ni-based catalysts in methane dry reforming showcase

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Stainless-steel honeycomb monoliths (square cell-shape/230 cpsi cylinders) were 3D-printed and used as support of a Ni/CeO2-ZrO2 powder deposited by washcoating. The resulting catalysts were characterized by XRF, SEM-EDX and H2-TPR, and tested in the dry reforming of methane reaction. In the 750–900 °C range, they showed competitive conversions (45–95%) and H2/CO ratio (0.84–0.94) compared to cordierite honeycombs with same catalyst loading and geometric characteristics, but did not require activation time thanks to better heat transfer. Both structured catalysts were stable in prolonged TOS experiments. The bare metallic monoliths exhibited significant activity at 900 °C due to their intrinsic nickel content.