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Single-Atom Cartridges: From Powder to Product

Objetivo

SAC3 takes the world’s first structured single-atom catalyst (demonstrated within the ERC StG “SAC_2.0” using vat photopolymerization) and does what laboratory discoveries rarely achieve: turns it into a manufacturable technology. The goal is not to discover a better catalyst but to validate a manufacturing process for obtaining atomically precise catalytic cartridges ready for integration into industrial continuous-flow reactors.
Conventional heterogeneous catalysts expose only 5-20% of their metal phase to reactants; single-atom catalysts raise this to nearly 100%. Yet, despite this exceptional efficiency, single-atom catalysts have not reached industrial reactors: produced exclusively as powders, they are incompatible with continuous-flow manufacturing, and the conventional route to overcome this (washcoating) requires high-temperature calcination that sinters isolated metal atoms into nanoparticles, destroying the atomic dispersion that defines their performance.
Our approach eliminates this problem at its source: support and metal precursors are co-formulated into a photopolymerizable resin and shaped layer-by-layer into any three-dimensional geometry to form the final cartridge in a single integrated process, with no binders, no washcoating, no calcination that destroys atomic dispersion. The result is a mechanically robust catalytic device verified by HAADF-STEM and EXAFS to contain exclusively atomically dispersed metal sites.
Preliminary data confirms the transformative potential of this platform: a structured Ni-based cartridge containing only 0.016 wt.% Ni, 100-fold less than the parent SAC powder, outperforms the powdered catalyst by 43% in productivity. SAC3 will validate these results at pre-industrial scale across multiple metal systems and reaction families, establishing the manufacturing, IP, and business foundations for a spinoff commercializing structured SAC cartridges to the global catalyst market.

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Programa(s)

Tema(s)

Régimen de financiación

HORIZON-ERC-POC - HORIZON ERC Proof of Concept Grants

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Convocatoria de propuestas

(se abrirá en una nueva ventana) ERC-2026-POC

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Institución de acogida

POLITECNICO DI MILANO
Aportación neta de la UEn
€ 110 000,00
Dirección
PIAZZA LEONARDO DA VINCI 32
20133 Milano
Italia
Región
Nord-Ovest Lombardia Milano
Tipo de actividad
Higher or Secondary Education Establishments
Enlaces
Coste total
Sin datos

Beneficiarios (2)