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<p>In this work, 3D printing-assisted ceramic monoliths based on MnO<sub>X</sub> were developed with different monolithic designs and MnO<sub>X</sub> loadings and these variables were evaluated in the catalytic oxidation of toluene. Among all tested configurations, biaxial channels exhibited lower catalytic activity; in contrast, uniaxial channels with sinusoidal geometries demonstrated the best catalytic performance. Monoliths with different MnO<sub>X</sub> loadings within the framework were also studied. Results indicate that high MnO<sub>X</sub> concentrations promote the formation of vitreous-like morphologies with smooth surface in the structural particles, leading to reduced catalytic activity due to decreased availability of active Mn sites. Conversely, the incorporation of α-Al<sub>2</sub>O<sub>3</sub> improved MnO<sub>X</sub> particle dispersion being the composition with 25&#xa0;wt% MnO<sub>X</sub> which achieved superior catalytic activity, reaching T<sub>90</sub> = 388&#xa0;°C; in this sense, the 3D printing-assisted ceramic monolith with a sinusoidal uniaxial channel design and&#xa0;25 wt% MnO<sub>X</sub> loading was identified as the most effective configuration for catalytic applications.Moreover, to demonstrate the potential capabilities of this type of monolithic structure through surface modification, further improvement was achieved through the incorporation of surface MnO<sub>X</sub>–CeO<sub>X</sub>, resulting in enhanced catalytic performance (T<sub>90</sub> = 311&#xa0;°C) and acceptable stability after three reaction cycles. The findings of this study highlight the feasibility of exploiting additive manufacturing techniques to engineer monolithic catalysts with tailored properties for advanced catalytic processes. In this context, the present study systematically evaluates different monolithic geometries and chemical framework compositions to determine the most effective configuration and MnO<sub>X</sub> loading for achieving superior catalytic performance. The overarching goal is to develop a cost-effective monolithic catalyst whose intrinsic activity arises from its integrated oxide-based framework, and which can be further improved through targeted surface engineering, optimized deposition techniques, or compositional tuning.</p> Graphical Abstract

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Experimental study on the effect of MnOX loadings and the design of the 3D-printed assisted ceramic monoliths on the toluene catalytic oxidation

  • 期刊论文

  • 发表日期：

    2026年4月19日

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  • S. I. Suárez-Vázquez,
  • I. D. De León-Abarte,
  • A. Cruz-López

摘要

In this work, 3D printing-assisted ceramic monoliths based on MnOX were developed with different monolithic designs and MnOX loadings and these variables were evaluated in the catalytic oxidation of toluene. Among all tested configurations, biaxial channels exhibited lower catalytic activity; in contrast, uniaxial channels with sinusoidal geometries demonstrated the best catalytic performance. Monoliths with different MnOX loadings within the framework were also studied. Results indicate that high MnOX concentrations promote the formation of vitreous-like morphologies with smooth surface in the structural particles, leading to reduced catalytic activity due to decreased availability of active Mn sites. Conversely, the incorporation of α-Al2O3 improved MnOX particle dispersion being the composition with 25 wt% MnOX which achieved superior catalytic activity, reaching T90 = 388 °C; in this sense, the 3D printing-assisted ceramic monolith with a sinusoidal uniaxial channel design and 25 wt% MnOX loading was identified as the most effective configuration for catalytic applications.Moreover, to demonstrate the potential capabilities of this type of monolithic structure through surface modification, further improvement was achieved through the incorporation of surface MnOX–CeOX, resulting in enhanced catalytic performance (T90 = 311 °C) and acceptable stability after three reaction cycles. The findings of this study highlight the feasibility of exploiting additive manufacturing techniques to engineer monolithic catalysts with tailored properties for advanced catalytic processes. In this context, the present study systematically evaluates different monolithic geometries and chemical framework compositions to determine the most effective configuration and MnOX loading for achieving superior catalytic performance. The overarching goal is to develop a cost-effective monolithic catalyst whose intrinsic activity arises from its integrated oxide-based framework, and which can be further improved through targeted surface engineering, optimized deposition techniques, or compositional tuning.

Graphical Abstract