Carbon-Free H2 Production from Ammonia Decomposition over 3D-Printed Ni-Alloy Structures Activated with a Ru/Al2O3 Catalyst

Hydrogen, with its high energy density and zero greenhouse gas emissions, is an exceptional energy vector, pivotal for a sustainable energy future. Ammonia, serving as a practical and cost-effective hydrogen carrier, offers a secure method for hydrogen storage and transport. The decomposition of ammonia into hydrogen is a crucial process for producing green hydrogen, enabling its use in applications ranging from clean energy generation to fueling hydrogen-powered vehicles, thereby advancing the transition to a carbon-free energy economy. This study investigates the catalytic performance of various 3D-printed porous supports based on periodic open cellular structures (POCS) and triply periodic minimal surface (TPMS) architecture manufactured from IN625 nickel alloy powder using the laser powder bed fusion (LPBF) technique. The POCS and TPMS, featuring geometries including BCC, Kelvin, and Gyroid, were analyzed for cell size, strut/sheet diameter, porosity, and specific surface area. Pressure drop analyses demonstrated correlations between structural parameters and fluid dynamics, with BCC structures exhibiting lower pressure drops due to their higher porosity and the open channel network. The dip/spin coating method was successfully applied to activate the supports with a commercial Ru/Al2O3 catalyst, achieving uniform coverage crucial for catalytic performance. Among the tested geometries, the Gyroid structure showed superior catalytic activity towards ammonia decomposition, attributed to its efficient mass transfer pathways. This study highlights the importance of structural design in optimizing catalytic processes and suggests the Gyroid structure as a promising candidate for improving reactor efficiency and compactness in hydrogen production systems.