Process of continuously producing plate-shaped catalyst and system therefor

A process of continuously producing catalyst plates comprising the steps of:

• forming slits in a continuous thin metal strip by use of a blade, said slits being perpendicular to the feed of the strip;
• expanding the strip in a direction perpendicular to the slits to form an expanded metal strip having formed therein meshes;
• correcting distortions in said expanded metal strip;
• degreasing said expanded metal strip;
• spraying molten metal onto said expanded metal strip to form roughened surfaces thereon;
• applying a catalytic substance onto the roughened surfaces of said expanded metal strip;
• clamping the strip resulting from the catalyst applying step between upper and lower continuous sheets to protect the roughened surfaces and to provide clean contact surfaces;
• applying pressure to the strip resulting from the catalyst applying step by applying pressure to the clean contact surfaces in order to bond the catalytic substance to the roughened surfaces and to flatten it;
• forming by pressing the thin expanded metal strip, to which the catalyst substance has been bonded, into a predetermind form;
• removing the upper and lower sheets;
• and
• shearing the continuous thin expanded metal strip thus formed into plate pieces.