Thermally conductive honeycombs for chemical reactors
AssigneeCorning Incorporated
InventorsWillard A. Cutler, Lin He, Anthony R. Olszewski, Charles M. Sorensen, Jr.
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Abstract
Monolithic metallic catalyst substrates offering improved heat conductivity are provided from metal powder extrusion batches of copper, tin, zinc, aluminum, iron, silver, nickel, and mixtures and alloys thereof by extrusion through a honeycomb extrusion die followed by drying and firing in a two stage firing process to oxidize organic extrusion batch components, remove residual oxides from the porous wall structure, and consolidate the metal powders to strong, integral honeycomb support structures.
Claims9
A method for making a monolithic metallic catalyst substrate comprising the steps of:
- compounding a metal powder extrusion batch comprising (i) a powder of a metal selected from the group consisting of copper, tin, zinc, aluminum, silver, iron, nickel, and mixtures and alloys thereof, and (ii) at least one carbon-containing temporary organic binder;
- extruding the batch through a honeycomb extrusion die to form a honeycomb substrate preform;
- heating the honeycomb substrate preform in an oxidizing atmosphere for a time and to a temperature at least sufficient to substantially remove the carbon-containing organic binder or extrusion aide by oxidation, thus to provide a carbon-free preform;
- and
- heating the carbon-free preform in a reducing atmosphere for a time and to a temperature at least sufficient to sinter the carbon-free preform to a unitary monolithic metallic catalyst substrate.
Dependencies are inferred from the claim text.