Metal foam element containing cobalt and method for producing same

A process for producing a supported catalyst, comprising the following steps:

• (a) providing a metal foam body A made of metallic cobalt, an alloy of nickel and cobalt, or overlying layers of nickel and cobalt;
• (b) applying an aluminum-containing powder MP to metal foam body A so as to obtain metal foam body AX;
• (c) thermally treating the metal foam body AX to achieve alloy formation between metal foam body A and aluminum-containing powder MP so as to obtain metal foam body B;
• wherein the maximum temperature in the thermal treatment of metal foam body AX is within a range from 680 to 715° C. for a total duration of between 5 and 240 seconds;
• (d) oxidizing metal foam body B so as to obtain metal foam body C;
• (e) applying a catalytically active layer comprising at least one support oxide and at least one catalytically active component to at least part of the surface of metal foam body C so as to obtain the supported catalyst;
• wherein the oxidative treatment of metal foam body B in step (d) is selected from the following:
• heating of metal foam body B while in contact with an oxidizing gas atmosphere without prior formation of aluminum hydroxide on the surface of the metal foam body;
• or
• heating of metal foam body B while in contact with an oxidizing gas atmosphere after aluminum hydroxide has previously been formed on the surface of the metal foam body.