Auto‐Pressurized Multi‐Stage Tesla‐Valve Type Microreactors in Carbon Monoliths Obtained Through 3D Printing: Impact of Design on Fluid Dynamics and Catalytic Activity

Abstract The present research exploits an innovative methodology for producing auto‐pressurized carbon microreactors with a precise and controlled structure analyzing the influence of their design on the fluid dynamics and their catalytic performance. Carbon monoliths with Tesla‐valve shape channels (Tesla, T, and modified Tesla, Tm) are synthesized through the combination of 3D printing and sol–gel process and further probed as Ni/CeO2 supports on CO2 methanation. The experimental results and mathematical modeling corroborated the improved performance obtained through the complex design compared to a conventional one. In addition to chaotic fluid flow induced by the deviation in flow direction, which improves the reagents‐active phase interaction, local pressure increases due to convergence of flows may enhance the Sabatier reaction according to Le Châtelier's principle. Conversely to straight channels, T and Tm are not affected by flow rate and presented chemical control. Tesla‐valve with curved angle (Tm) improved the mass transfer, achieving higher conversion and ≈30% reaction rate increase regarding right angle (T). Thus, this auto‐pressurized multi‐stage Tesla‐valve monolith opens the gate to design specific and advanced functional materials for multitude chemical reactions where not only the reactant‐active phase contact can be maximized but also the reaction conditions can be controlled to maximize the reaction kinetics.