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A New Generation of Activated Carbon Adsorbent Microstructures

OAI: oai:purehost.bath.ac.uk:publications/3c1066f8-c06b-44e1-b32a-f045b1b59764 • DOI: https://doi.org/10.1002/advs.202406551
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Abstract

This work presents the successful manufacture and characterization of
bespoke carbon adsorbent microstructures such as tessellated (TES) or
serpentine spiral grooved (SSG) by using 3D direct light printing. This is the
first time stereolithographic printing has been used to exert precise control
over specific micromixer designs to quantify the impact of channel structure
on the removal of n-butane. Activated microstructures achieved nitrogen
Brunauer Emmett Teller (BET) surface areas up to 1600 m2 g−1 while
maintaining uniform channel geometries. When tested with 1000 ppm
n-butane at 1 L min−1, the microstructures exceeded the equilibrium loading
of commercial carbon-packed beds by over 40%. Dynamic adsorption
breakthrough testing using a constant Reynolds number (Re 80) shows that
complex micromixer designs surpassed simpler geometries, with the SSG
geometry achieving a 41% longer breakthrough time. Shorter mass transfer
zones were observed in all the complex geometries, suggesting superior
kinetics and carbon structure utilization as a result of the micromixer-based
etched grooves and interlinked channels. Furthermore, pressure drop testing
demonstrates that all microstructures had half the pressure drop of
commercial carbon-packed beds. This study shows the power of leveraging
3D printing to produce optimized microstructures, providing a glimpse into
the future of high-performance gas separation.