CSMs - Catalytic Static Mixers Challenge The current methods for heterogeneous catalysis using packed bed reactors pose many limitations. Fluid flow through the bed, as well as temperature and concentration gradients, can often be highly non-uniform, making heat control difficult - especially on large scale. For liquid phase applications, pressure drop along the bed can also be highly problematic. The size and shape of catalyst particles determine the performance of the catalytic reaction and the physical processes occurring inside the reactor such as fluid flow, mixing and heat, and mass transfer, often leading to undesirable limitations. A different approach is needed. Working with additive manufacturing experts, CSIRO are utilising state-of-the art technology to develop a hierarchical catalytic reactor approach. This new method involves a tailored mixing solution which can be addressed by the 3D printed design of the static mixer married with a range of active catalyst coatings for different catalytic reactions. Additionally the tubular design of the continuous flow reactor provides superior process control compared with packed bed columns or stirred batch vessels. These processes make this technology a versatile and efficient tool for R&D and production. Capability Drawing on the multi-disciplinary expertise at the CSIRO, we have delivered a new method for heterogeneous catalytic reactions - catalytic static mixers (CSMs). With simple and well established design this innovative solution aims to provide an elevated approach to tubular reactor technology. Using 3D printing capabilities, novel metal scaffolds are designed and manufactured before the catalyst is directly deposited via electroplating, cold spraying, or other deposition methods. The CSMs can be readily inserted into reactor tubes, allowing for easy changeover of catalyst. The benefits of utilising metal scaffolds, which have good mechanical stability, are significant and include: SUPERIOR PROCESS CONTROL In comparison to most catalyst bed systems, temperature within the newly designed CSM reactors are far more controllable. The design of the mixers ensure that pressure drop is low and mixing is efficient. Detail of 3d printer printing a metal piece MANUFACTURING www.csiro.au