Patent ID: 6881703
Filing Date: 2005-04-19
Classification: B01J,B22F,C01B,Y02P

Abstract:
1. 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.