3D printed nickel catalytic static mixers made by corrosive chemical treatment for use in continuous flow hydrogenation

Catalytic static mixers, 3D printed from nickel alloys, were treated with etching or leaching solutions to activate their surfaces for use in hydrogenation of alkenes, aldehydes and nitro-groups. Their performance was benchmarked against industrial standard alumina catalysts, using a tubular continuous flow reactor. These novel structured catalysts were additively manufactured from printer-grade Monel and Inconel powders. Especially the Monel-type catalysts, consisting predominantly of nickel and copper by weight, presented a surface layer significantly enriched in nickel after the leaching protocol, which resulted in a high catalytic activity and a surprising selectivity towards unsubstituted double bonds.