Catalyst assembly providing high surface area for nitric acid and/or HCN synthesis

A catalyst assembly for use in the oxidation of ammonia comprising:

• a plurality of wire mesh sheets containing a catalytic metal having broad foraminous surfaces, the adjacent foraminous surfaces of said sheets being in intimate nested relation to each other,
• said surfaces being non-planar along the majority of their area and defining a plurality of corrugations;
• wherein the surface area of said catalyst assembly is about 1.6 to about 1.7 times that of planar catalyst gauze assemblies of the same outer perimeter;
• wherein said catalyst assembly provides increased catalytic surface area with lower pressure drop.

In a method for the reaction of ammonia to form a reaction by-product selected from the group consisting of nitric acid and hydrogen cyanide comprising the passage of said ammonia through a reactor containing a catalyst for the conversion of said ammonia to said by-product, the improvement comprising the passage of said ammonia through a catalyst assembly, said catalyst assembly comprising:

• a plurality of wire mesh sheets containing a catalytic metal having broad foraminous surfaces, the adjacent foraminous surfaces of said sheets being in intimate nested relation to each other,
• said surfaces being non-planar along the majority of their area and defining a plurality of corrugations;
• wherein one or more of said sheets are provided with coatings which assist in the start-up of the oxidation of ammonia;
• wherein said catalyst assembly provides increased catalytic surface area with lower pressure drop.