Process for preparing catalyst powder

A process for producing a catalytic convertor, comprising:

• preparing a catalyst slurry comprising a catalyst, a liquid carrier, a templating agent, and a catalyst substrate;
• drying the catalyst slurry to obtain a raw catalyst powder;
• heating the raw catalyst powder in a first controlled atmosphere to get a pyrolyzed catalyst powder;
• calcining the pyrolyzed catalyst powder in a second controlled atmosphere to get a calcined catalyst powder;
• and
• fabricating a catalytic surface comprising the calcined catalyst powder.

A process for producing a NOx catalytic convertor, comprising:

• preparing a catalyst slurry comprising silver, alumina, an alcohol, and a templating agent;
• spray drying the catalyst slurry to get a raw catalyst powder;
• heating the raw catalyst powder in an inert atmosphere to get a pyrolyzed catalyst powder;
• calcining the pyrolyzed catalyst powder in a controlled oxygen atmosphere to get a calcined catalyst powder comprising silver templated mesoporous alumina (Ag-TA);
• mixing the calcined catalyst powder with a liquid to form a calcined catalyst powder slurry;
• and
• washcoating the calcined catalyst powder slurry onto a monolith support.