Raney catalyst preparation by gas atomization of molten alloy

A Raney type catalyst, wherein the catalyst is made by a method comprising melting together a Raney metal and aluminum to form a molten alloy mixture;

• pouring the molten mixture through a nozzle, directing a gas jet on to the mixture to form a spray of droplets, which droplets are directed on to a metallic substrate, wherein the material of the substrate and the thickness, the latent heat, and the superheat of the sprayed material are selected such that, upon initial contact with the substrate, the temperature is sufficiently high for an exothermic reaction to take place between the alloy mixture and the substrate such that intermetallic bonds are formed therebetween;
• and subsequently chemically removing at least some of the aluminum from the sprayed material.

A method of producing a Raney type catalyst, the method comprising melting together a Raney metal and aluminum to form a molten alloy mixture;

• pouring the molten mixture through a nozzle, directing a gas jet on to the mixture to form a spray of droplets in a substantially non-reactive atmosphere, which droplets are directed on to a metallic substrate, wherein the material of the substrate and the thickness, the latent heat, and the superheat of the sprayed material are selected such that, upon initial contact with the substrate, the temperature is sufficiently high for an exothermic reaction to take place between the alloy mixture and the substrate such that intermetallic bonds are formed therebetween;
• and subsequently chemically removing at least some of the aluminum from the sprayed material.