METHOD OF PRODUCING CATALYST Russian patent published in 2021 - IPC B01J37/02 B01J32/00 B01J35/10 B22F3/105 B29C64/194 B29C71/00 B29C64/165 B01D53/86 

FIELD: chemistry.

SUBSTANCE: present invention relates to production of catalysts using a substrate prepared by additive layer-by-layer production. Method of producing catalyst or catalyst precursor includes: (i) combining substrate material in form of particles with binder to form billet mixture, (ii) forming billet mixture layer, (iii) applying a binding solvent from the print head to the workpiece mixture layer in accordance with a given pattern for bonding the substrate material in the form of particles, (iv) repeating steps (ii) and (iii) layer by layer, (v) removing unbound material, and (vi) drying and optionally calcination to form a substrate structure, (vii) applying a suspension of a catalyst compound in the form of particles in a carrier fluid to a substrate structure obtained by additive layer-by-layer production with formation of a substrate-impregnated substrate, and (viii) drying and optionally calcining a substrate-impregnated soot to form a catalyst precursor or catalyst, wherein the average particle size (D50) of the catalyst compound in the form of particles in the suspension is in range of 1–50 mcm, and the substrate structure has porosity from 0.02 to 1.4 ml/g, and the average particle size of the catalyst compound in the form of particles is less than the pore size distribution.

EFFECT: this method provides catalysts with improved properties compared to conventional processes and enables to use catalyst compounds not suitable for impregnation by soluble salts.

23 cl, 13 tbl, 1 dwg, 5 ex