| abstract |
A method for producing a catalyst or catalyst precursor comprises: applying a slurry of a particulate catalyst compound in a carrier fluid to an additive layer manufacturing support structure to form a slurry impregnated support; and drying or optionally calcining the slurry impregnated support to form a catalyst or catalyst precursor, wherein the mean particle size of the particulate catalyst compound in the slurry is in the range 1-50 µm and the support structure has ≥ 0.02 ml/g. The support structure may be manufactured by steps comprising: combining a particulate support material with a binder to form a pre-form mixture; forming a layer of the preform mixture; applying a binding solvent from a printhead to the layer of preformed mixture according to a predetermined pattern to bind the particulate support material; repeating the previous two steps layer upon layer; removing unbound material and drying or optionally calcining to form the support structure. The particulate support material may be a powder with a particle size in the range of 0.1-400 µm and may comprise an alumina, metal-aluminate, silica, alumina-silicate, cordierite, titanium (IV) oxide cerium (IV) oxide, zinc oxide, or a mixture thereof, a zeolite, a metal powder, silicon carbide, silicon nitride or carbon. |