Catalyst manufacturing method

1. A process comprising contacting a reactant mixture with a catalyst under conditions to effect a catalysed reaction or sorption,

wherein the catalyst is a particulate catalyst with a cross-sectional size in the range 1-50 mm and an aspect ratio in the range 0.5 to 5, and the particulate catalyst is produced using a 3D additive layer method comprising:

(i) forming a layer of a powdered catalyst support material comprising an alumina, metal-aluminate, silica, alumina-silicate, titania, zirconia, zinc oxide, or a mixture thereof;

(ii) binding the powder in said layer according to a predetermined pattern,

(iii) repeating (i) and (ii) layer upon layer to form a shaped unit, and

(iv) applying a catalytic material to said shaped unit.

2. A process according to claim 1 comprising a catalysed reaction selected from hydroprocessing including hydrodesulphurisation, a hydrogenation, steam reforming including pre-reforming, catalytic steam reforming, autothermal reforming and secondary reforming and reforming processes used for the direct reduction of iron, catalytic partial oxidation, a water-gas shift including isothermal-shift, sour shift, low-temperature shift, intermediate temperature shift, medium temperature shift and high temperature shift reactions, a methanation, a hydrocarbon synthesis by the Fischer-Tropsch reaction, methanol synthesis, ammonia synthesis, ammonia oxidation and nitrous oxide decomposition reactions, or selective oxidation or reduction reactions of internal combustion engine or power station exhaust gases.

3. A process according to claim 1 comprising a sorption selected from the recovery of sulphur compounds or heavy metals such as mercury and arsenic from contaminated gaseous or liquid fluid streams, or particulate matter from the exhaust gases of internal combustion engines or power stations.

4. A process according to claim 1 wherein the catalytic material applied to the shaped unit comprises a metal, metal compound or a zeolite.

5. A process according to claim 4 wherein the metal, metal compound or zeolite is applied to the shaped unit from a solution or dispersion of the metal, metal compound or zeolite.

6. A process according to claim 5 wherein the metal, metal compound or zeolite comprises one or more metals selected from the group consisting of Na, K, Mg, Ca, Ba, Al, Si, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Ru, Rh, Pd, Ag, Sn, Sb, La, Hf, W, Re, Ir, Pt, Au, Pb, or Ce.

7. A process according to claim 1 wherein the powdered material has an average particle size, D 50 , in the range 1 to 200 micrometers.

8. A process according to claim 1 wherein the powder in each layer is bound together with a binder.

9. A process according to claim 8 wherein a burnout additive is included in the catalyst powder or binder to control the porosity of the resulting shaped unit.

10. A process according to claim 1 wherein the shaped unit is subjected to a heating step.

11. A process according to claim 1 wherein the shaped unit, comprising one or more reducible metal compounds, is subjected to a reduction step.

12. A process according to claim 1 wherein the shaped unit is a wire-frame structure or a skeletal framework containing a void space within which may have multiple internal strengthening rods.

13. A method for the preparation of shaped units useful as catalysts in a catalysed reaction or sorption, wherein;

the shaped units are produced using an additive layer method comprising:

(i) forming a layer of a powdered catalyst or catalyst support material,

(ii) binding or fusing the powder in said layer according to a predetermined pattern,

(iii) repeating (i) and (ii) layer upon layer to form a shaped unit, and

(iv) optionally applying a catalytic material to said shaped unit;

and the catalysed reaction is selected from hydroprocessing including hydrodesulphurisation, a hydrogenation, steam reforming including pre-reforming, catalytic steam reforming, autothermal reforming and secondary reforming and reforming processes used for the direct reduction of iron, catalytic partial oxidation, a water-gas shift including isothermal-shift, sour shift, low-temperature shift, intermediate temperature shift, medium temperature shift and high temperature shift reactions, a methanation, a hydrocarbon synthesis by the Fischer-Tropsch reaction, methanol synthesis, ammonia synthesis, ammonia oxidation and nitrous oxide decomposition reactions, or selective oxidation or reduction reactions of internal combustion engine or power station exhaust gases; and

the sorption is selected from the recovery of sulphur compounds or heavy metals such as mercury and arsenic from contaminated gaseous or liquid fluid streams, or particulate matter from the exhaust gases of internal combustion engines or power stations.