Mold for manufacturing a ceramic filling member

Abstract

A mold for manufacturing a filler member from a liquid ceramic composition, the mold comprising a first part and a second part, wherein the first part and / or the second part comprises an open mold cavity, and wherein the first part and the second part are operable to engage to form a closed mold cavity, wherein the mold further comprises a reservoir forming member, and wherein the mold is operable to move from an open position, in which the first part and the second part are at least partially spaced apart such that the reservoir member forms a reservoir cavity and the mold cavity is open, to a partially closed position, in which the position of the reservoir cavity has been moved relative to the mold cavity and / or the volume of the reservoir cavity has been reduced, and then to a closed position, in which the first part and the second part are engaged such that the mold cavity is closed.

Description

Technical Field

[0001] This invention relates to molds for manufacturing packed components for packed beds, and more particularly to supports and supported catalysts for catalysts. More specifically, this invention relates to molds for manufacturing ceramic catalyst supports and supported catalysts for processes such as steam reforming and direct reduction of iron production. Background Technology

[0002] Metal catalysts used in industrial production processes, such as steam reforming and direct reduced iron production, exhibit higher activity when finely divided into small particles to increase the metal surface area. A large metal surface area can be maintained during such reactions by dispersing the metal particles on a refractory support. Another advantage of using a catalyst support in such processes is that only a small amount of more expensive catalytic metal needs to be dispersed onto a large amount of abundant, inexpensive support material, thus significantly reducing the cost of catalytic materials required for commercial-scale production.

[0003] In many such processes, the catalytic reaction needs to be very fast and confined by the pellet surface. Therefore, the reaction will depend on the geometric surface area of ​​the supported catalyst. Furthermore, supported catalysts with low internal surface area (BET) and such small internal pore volume typically exhibit low activity in such processes. The strength of the support is also important, as breakage during loading, operation, and effluent of the supported catalyst can reduce activity and increase delays and costs. For example, in the Midrex process for direct reduced iron (DRI), the catalyst undergoes high levels of mechanical handling and thermal cycling, as does the steam reforming catalyst. Additionally, the supported catalyst should provide good heat transfer characteristics while maintaining a low pressure drop.

[0004] In such industrial processes, the support used for the catalyst is typically prepared by extruding, pelletizing or granulating ceramic powder, and then calcining the green body.

[0005] However, it has been found that such methods can only provide limited carrier geometry and physical properties. For example, such carriers can achieve high strength, but at the cost of small geometric surface area and poor porosity.

[0006] Therefore, there is a need for improved supports for catalysts, which have a better combination of desired properties that can be produced economically. Thus, the object of various aspects of the present invention is to solve one or more of the above-mentioned or other problems. Summary of the Invention

[0007] According to a first aspect of the invention, a mold is provided for manufacturing a filling member from a liquid ceramic composition. The mold includes a first component and a second component, wherein the first component and / or the second component includes an open mold cavity, and wherein the first component and the second component are operable to engage to form a closed mold cavity. The mold further includes a reservoir forming member, and wherein the mold is operable to move from an open position to a partially closed position, and then to a closed position. In the open position, the first component and the second component are at least partially spaced apart such that the reservoir forming member forms a reservoir cavity and the mold cavity is open. In the partially closed position, the position of the reservoir cavity has been moved relative to the mold cavity, and / or the volume of the reservoir cavity has been reduced. In the closed position, the first component and the second component engage such that the mold cavity is closed.

[0008] According to a second aspect of the present invention, a method for producing a filling member for use in a filled bed is provided, the method comprising the following steps:

[0009] a. Arranging a mold including a first component and a second component in an open position, wherein the first component and / or the second component includes an open mold cavity, and wherein the mold further includes a reservoir forming member, wherein in the open position, the first component and the second component are at least partially spaced apart such that the reservoir forming member forms a reservoir cavity and the reservoir cavity is open;

[0010] b. Fill the reservoir cavity of the mold at least partially with a liquid ceramic composition;

[0011] c. Move the mold to a partially closed position, causing the position of the reservoir cavity to shift relative to the mold cavity and / or the volume of the reservoir cavity to decrease, so that a portion of the liquid ceramic composition is transferred from the reservoir cavity to the open mold cavity; and

[0012] d. The mold is moved to the closed position, where the first and second components engage to close the mold cavity, thereby retaining a portion of the liquid ceramic composition within the closed mold cavity to form a green body; and

[0013] e. Optionally, the green blank is heated;

[0014] f. To demold the green piece; and

[0015] g. Optionally, the green body is calcined to produce a filling component.

[0016] According to a third aspect of the invention, a molding apparatus is provided for use in the production of filler components from a liquid ceramic composition. Suitably, a molding apparatus is provided for use in a method according to a second aspect of the invention, the molding apparatus comprising: a mold according to a first aspect of the invention; and a guide member operable to arrange the mold in an open position.

[0017] According to a fourth aspect of the invention, a packing member is provided for use in a packed bed, the packing member preferably serving as a catalyst carrier in a packed bed reactor, the packing member being obtained by molding a liquid ceramic composition in a mold according to a first aspect of the invention, by a method according to a second aspect of the invention, and / or by molding a liquid ceramic composition in a molding apparatus according to a third aspect of the invention.

[0018] Both the first and second components may include open mold cavities. Suitably, the mold cavity of the first component and the mold cavity of the second component may be open partial mold cavities, and the first and second components of the mold are operable to engage such that a partial mold cavity of the first component aligns with a partial mold cavity of the second component to form a closed, enlarged mold cavity. When used herein, "open" mold cavity may mean that a filling member or green body, or a portion thereof, is operable to be removed from the mold cavity via the same orifice through which the liquid ceramic composition was introduced into the mold cavity. When used herein, "closed" mold cavity may mean that the liquid ceramic composition is retained within the mold cavity such that it cannot leave the mold cavity.

[0019] The first component and / or the second component may include multiple open mold cavities. Suitablely, each of the first component and / or the second component may include multiple open partial mold cavities.

[0020] The mold cavity may include a texture operable to create a surface structure on the filling member. Suitablely, the surfaces of the mold cavity operable to contact the liquid ceramic composition during molding may include a texture.

[0021] The mold cavity may include pins operable to form holes in the filling member, such as holes extending through the filling member. Suitably, the mold cavity may include at least two pins, such as at least three or at least four pins. The pins may be arranged on the bottom surface of the mold cavity and extend upward toward the opening of the mold cavity. The pins may be substantially centrally arranged on the bottom surface of the mold cavity. The pins may be cylindrical.

[0022] The reservoir component is operable to form a reservoir cavity that can receive and hold a liquid ceramic composition. The reservoir cavity may not be a mold cavity, so that in the closed position, the reservoir cavity is essentially inoperable to hold a portion of the composition or form a molded product.

[0023] The reservoir component may include a first reservoir component disposed on a first mold component and a second reservoir component disposed on a second mold component, wherein the first and second reservoir components are operable to cooperate in engagement to form a reservoir cavity. Suitably, the first and second reservoir components may be a convex reservoir component and a concave reservoir component, such that the convex reservoir component is operable to be received into the concave reservoir component to form a reservoir cavity. The convex reservoir component may be in the form of a tongue, and the concave reservoir component may be in the form of a groove. Suitably, the convex and concave reservoir components are operable to form a tight fit upon engagement. "Tight fit" as used herein refers to a fit operable to prevent the liquid ceramic composition from passing through the engaged reservoir components.

[0024] The first mold component and / or the second mold component may include reservoir members, suitably tongues or grooves, extending along opposite sides of the mold cavity of the mold component, and suitably extending longitudinally. Suitably, both the first and second mold components may include a mold cavity, and the first reservoir member includes tongues extending along opposite sides of the mold cavity of the mold component, and the second reservoir member includes grooves extending along opposite sides of the mold cavity of the mold component. The reservoir members of the mold component may also include base reservoir members extending between the side reservoir members. The base reservoir members may extend laterally along the mold component. The base members may be disposed below the mold cavity of the mold component. Suitably, the first reservoir member may include base tongues extending between opposite side tongues, and / or the second reservoir member may include base grooves extending between opposite side grooves. Such reservoir member configurations may be U-shaped, wherein the side reservoir members extend longitudinally along the mold component, and the base reservoir members extend laterally along the mold component between the side reservoir members. The base reservoir member may provide the bottom inner surface or base of the reservoir cavity during use. The side reservoir members may provide the side surfaces of the reservoir cavity during use. The surface of the mold member extending between the side reservoir members may also include a mold cavity, providing a front and rear surface of the reservoir cavity. Typically, the reservoir cavity includes an opening. The opening may extend between the ends of the side reservoir members that are not connected to the base reservoir member. Suitably, the opening of the reservoir cavity may extend laterally across the mold member, generally substantially parallel to the base reservoir member.

[0025] Suitable, the first mold component and / or the second mold component may include a group of multiple mold cavities. Side reservoir members may be arranged to extend along opposite sides of the group of mold cavities. Base members may be arranged to extend below the group of mold cavities.

[0026] The reservoir components of the mold component may be arranged on the same surface as the mold cavity. The reservoir components of the mold component may be arranged such that the engagement of the reservoir components is operable to align these portions of the mold cavity on the mold component, thereby forming an enlarged mold cavity in a closed position.

[0027] Therefore, when the mold is in the open position, the reservoir components can be operated to engage to form a reservoir cavity, which can be operated to receive the liquid ceramic composition through its opening and then retain the liquid ceramic composition within the reservoir cavity. Suitablely, when the mold is in the open position, the mold cavity can be arranged within the initial reservoir cavity. The mold cavity can also be arranged outside the initial reservoir cavity when the mold is in the open position. As the mold moves from the open position to the partially closed position and then to the closed position, the reservoir components of the mold assembly can be operated to engage further, causing the reservoir cavity to move along the group of mold cavities to close the now-filled mold cavity in the initial reservoir cavity and transfer the remaining composition to the repositioned reservoir cavity and the new mold cavity. This movement can continue until the reservoir components are fully engaged, causing the mold cavity to close properly through the engagement between the mold components above the mold cavity. Typically, the reservoir cavity has a smaller volume than the combined volume of the mold cavities.

[0028] The first mold component and / or the second mold component may be elastically deformable. The mold can be operated to move from an open position (wherein the first and second components are partially spaced apart by deforming the mold components) to a partially closed position by reducing the deformation of the mold components, and then to a closed position by further reducing the deformation of the mold components.

[0029] Suitable, the first mold component and the second mold component may be formed of a polymer material, such as silicone. The silicone may be formed of a two-part silicone composition comprising a silicone resin and a curing agent or catalyst.

[0030] The Shore hardness of the material forming the first mold component and / or the second mold component may be at least 5, such as at least 10, or at least 15, such as at least 20. The Shore hardness of the material forming the first mold component and / or the second mold component may be at most 40, such as at most 35, or at most 32, such as at most 30. The Shore hardness of the material forming the first mold component and / or the second mold component may be from 5 to 40, such as from 10 to 35, or from 15 to 32, such as from 20 to 30. Advantageously, materials with Shore hardness within the above ranges have been found to provide a mold according to the invention that is flexible enough to allow efficient molding while maintaining sufficient shape and rigidity. As described herein, Shore hardness is measured using ASTM D2240 Type A.

[0031] The shrinkage rate of the material forming the first mold component and / or the second mold component may be at most 1%, such as at most 0.5%, or at most 0.4%, such as at most 0.3%. Advantageously, it has been found that materials with shrinkage rates within the above range provide a mold that improves the alignment between mold components. As described herein, shrinkage rate may refer to the amount of dimensional change, appropriately within a period of one week, such as within a period of one month or three months.

[0032] The mold component may include a retaining member operable to assist in maintaining the alignment of the mold component. The mold component may include a retaining member operable to assist in maintaining the alignment of the mold component during dispensing of the liquid ceramic composition into the mold. The dispensing retaining member may be spaced apart from the reservoir cavity, for example, without providing an inner surface of the reservoir cavity. Typically, the dispensing retaining member is not directly attached to the reservoir component. The dispensing retaining member may include cooperating members disposed on a first mold component and a second mold component. Suitably, the cooperating dispensing retaining member may be convex and concave, such that a convex retaining member can be received in a concave retaining member to assist in the alignment of the mold component. The convex retaining member may be a tongue and the concave alignment member may be a groove. The retaining member of the mold component may be disposed below the base of the reservoir cavity. The retaining member may extend laterally along the mold component, substantially parallel to the base of the reservoir cavity, or the base reservoir component. Advantageously, the use of a dispensing retaining member allows for the formation of a larger initial reservoir cavity while maintaining good alignment of the mold component.

[0033] The mold components may include post-dispensing retaining members operable to assist in maintaining alignment of the mold cavity after dispensing the liquid ceramic composition. The post-dispensing retaining member may be disposed outside the reservoir cavity, for example, without providing an inner surface to the reservoir cavity. The post-dispensing retaining member may include cooperating members disposed on a first mold component and a second mold component. Suitably, the cooperating post-dispensing retaining member may be convex and concave, such that a convex retaining member can be received within a concave retaining member to assist in maintaining alignment of the mold components. The convex retaining member may be a tongue and the concave alignment member may be a groove. The post-dispensing retaining member may be laterally disposed adjacent to the mold cavity or a group of mold cavities. The retaining member may extend laterally along the mold component. The post-dispensing retaining member may include a group of multiple retaining members disposed on each side of the mold cavity or a group of mold cavities, suitably laterally adjacent to the mold cavity or group of mold cavities. Each group of retaining members may include at least two retaining members, such as at least three, spaced apart longitudinally along the mold component. Advantageously, the use of a post-dispensing retainer allows for improved alignment retention between mold components after the composition has been dispensed.

[0034] The mold component may include a recess disposed above the mold cavity, suitably above the opening of the reservoir cavity. Typically, the recess is elongated and may extend substantially parallel to the base of the reservoir cavity or the base reservoir member. When the mold component reaches the closed position, the recess can be operated to receive any excess composition contained in the reservoir cavity.

[0035] The mold component may include guide members. Suitably, the guide members may extend outwardly from the mold component. The mold component may include guide members disposed on each of two opposing surfaces of the mold component, suitably disposed on two opposing side surfaces of the mold component. The mold component may include at least three guide members, such as at least four, at least five, or at least six guide members, on each of the two opposing surfaces of the mold component. The surface of the mold component may include guide members disposed at opposing ends of the surface and intermediate guide members disposed between the end guide members.

[0036] The mold component may include a reinforcing member, suitably more rigid than the body of the mold component. The reinforcing member may be at least partially disposed within the body of the mold component. The reinforcing member may extend substantially from one end of the mold component body to the other, such as to opposite ends. The reinforcing member may protrude from the mold component to provide a guiding member. Suitably, the reinforcing member may protrude on opposite sides of the mold component to provide guiding members on opposite sides of the mold component. Thus, guiding members may be provided by protruding reinforcing members.

[0037] The filling component can be formed from a casting molding composition or slurry, such as a clay or non-clay castable composition, a liquid cement or gel casting composition. Therefore, the liquid ceramic composition can be a gel casting composition, and suitably, the composition may include ceramic materials, organic binder components, and optional pore-forming components.

[0038] The organic binder component can be operated to be substantially removed from the filler after molding, preferably by heat treatment, more preferably during the calcination of the filler.

[0039] Organic adhesive components may include polymerizable components, which may suitably include polymerizable monomers and crosslinking components, wherein the adhesive components are operable to polymerize to form (copolymer) polymers.

[0040] The polymerizable monomer may include: one or more types of olefinically unsaturated monomers, such as acrylic acid monomers or derivatives of acrylic acid monomers, the derivatives of which are such as acrylamide monomers; and / or vinyl monomers, such as monomers selected from one or more of methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM), hydroxyethylacrylamide (hEAM), and / or N-vinyl-2-pyrrolidone (NVP). Preferably, the polymerizable monomer includes one or more acrylamide monomers, more preferably monomers selected from one or more of methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM), and hydroxyethylacrylamide (hEAM). Most preferably, the polymerizable monomer includes MAM.

[0041] The crosslinking component may be selected from one or more of diene-bonded unsaturated monomers, acrylates, and / or polyethylene glycol-substituted acrylic monomers, wherein the diene-bonded unsaturated monomer is such as a diacrylate monomer or a derivative thereof, and the derivative thereof is such as a diacrylamide monomer. The crosslinking component may be selected from one or more of poly(ethylene glycol) dimethacrylate (PEGDMA), N,N'-methylenebis(acrylamide) (BIS), ammonium acrylate, and PEG-methyl ethyl acrylate (PEGMEM), preferably from one or more of poly(ethylene glycol) dimethacrylate (PEGDMA) and N,N'-methylenebis(acrylamide) (BIS).

[0042] The organic binder component may be formed from 40 wt% to 95 wt% of polymerizable monomers and 60 wt% to 5 wt% of crosslinking components, such as 50 wt% to 90 wt% of polymerizable monomers and 50 wt% to 10 wt% of crosslinking components, or 55 wt% to 85 wt% of polymerizable monomers and 45 wt% to 15 wt% of crosslinking components, or 60 wt% to 80 wt% of polymerizable monomers and 40 wt% to 20 wt% of crosslinking components, such as 65 wt% to 75 wt% of polymerizable monomers and 35 wt% to 25 wt% of crosslinking components.

[0043] The composition may also include a polymerization accelerator that can be operated to accelerate the polymerization of the binder components. The polymerization accelerator can be any suitable accelerator. For example, it can be tetramethylethylenediamine (TEMED).

[0044] The composition may also include an initiator operable to initiate polymerization of the binder components. The initiator can be any suitable initiator. The initiator can be a free radical initiator. For example, the initiator can be ammonium persulfate and / or potassium persulfate.

[0045] The pore-forming material can be manipulated to be removed from the filler after molding, preferably by heat treatment, more preferably during calcination of the filler. The pore-forming material may be selected from one or more of microspheres, starch, seeds, and / or cellulose.

[0046] Pore-forming materials can have the following particle size distribution, where D 10 The diameter is 5 μm to 100 μm, preferably 10 μm to 75 μm, more preferably 15 μm to 50 μm, and most preferably 20 μm to 40 μm. The D-type of the pore-forming material... 50 The diameter can range from 50 μm to 200 μm, preferably from 75 μm to 175 μm, more preferably from 90 μm to 160 μm, and most preferably from 100 μm to 150 μm. The D-type pore-forming material... 90 The size can be from 120 μm to 300 μm, preferably from 150 μm to 270 μm, more preferably from 170 μm to 250 μm, and most preferably from 185 μm to 235 μm.

[0047] Ceramic materials can be refractory ceramic materials. Ceramic materials may include alumina, aluminum silicate, magnesium aluminate, calcium aluminate, zirconium oxide, silicon dioxide, titanate, carbon and / or magnesium oxide.

[0048] Ceramic materials can have the following particle size distribution, where D 10 The micrometer diameter (D) is 0.1 μm to 20 μm, preferably 0.5 μm to 10 μm, more preferably 1 μm to 5 μm, and most preferably 1.5 μm to 3 μm. 50 The diameter can range from 0.5 μm to 30 μm, preferably from 1 μm to 25 μm, more preferably from 1.5 μm to 20 μm, and most preferably from 2 μm to 15 μm. The D-type pore-forming material... 90 The size can be from 10 μm to 100 μm, preferably from 15 μm to 80 μm, more preferably from 20 μm to 70 μm, and most preferably from 25 μm to 60 μm.

[0049] The ceramic material can be ceramic powder. The ceramic powder can be ball-milled or spray-dried. Advantageously, it has been found that ball-milled or spray-dried ceramic powder provides properties that are easier to cast.

[0050] The composition or filling component may include a promoter that can be operated to increase the reactivity of the main reaction and / or reduce undesirable side reactions. The promoter may be selected from one or more oxides of lanthanum, copper, magnesium, manganese, potassium, calcium, zirconium, barium, cerium, sodium, lithium, molybdenum, yttrium, cobalt, and chromium.

[0051] The composition may also include a carrier, such as an aqueous carrier. Suitablely, the composition may be an aqueous ceramic slurry.

[0052] The composition may include other additives. For example, the composition may include dispersants, such as polymer salts, for example, salts of polyacrylic acid, preferably ammonium salts of polyacrylic acid. Suitable dispersants may be selected from one or more of Ecodis P90, Narlex LD42, and Dispex A40.

[0053] The composition may include 0.1% to 10% of polymerizable monomers based on the dry weight of the composition, preferably including 0.5 wt% to 8 wt% of polymerizable monomers, more preferably including 1 wt% to 6 wt% of polymerizable monomers, such as 1.5 wt% to 5 wt% of polymerizable monomers, and most preferably 2 wt% to 4 wt% of polymerizable monomers.

[0054] The composition may include 0.1% to 10% of a crosslinking component based on the dry weight of the composition, preferably 0.5 wt% to 8 wt% of a crosslinking component, more preferably 0.75 wt% to 6 wt% of a crosslinking component, such as 1 wt% to 5 wt% of a crosslinking component, and most preferably 1 wt% to 4 wt% of a crosslinking component.

[0055] The composition may comprise 50% to 95% ceramic material by dry weight of the composition, preferably 50 wt% to 90 wt% ceramic material, more preferably 55 wt% to 85 wt% ceramic material, and most preferably 60 wt% to 80 wt% ceramic material. The filler component may comprise at least 75% ceramic material by dry weight of the composition, preferably at least 85 wt% ceramic material, more preferably at least 90 wt% ceramic material, such as at least 95 wt% ceramic material, and most preferably at least 97 wt% ceramic material.

[0056] The composition may include >0% to 40% of a pore-forming component based on the dry weight of the composition, preferably including 0.5wt% to 30wt% of a pore-forming component, more preferably 2wt% to 25wt% of a pore-forming component, such as 3wt% to 20wt% of a pore-forming component, and most preferably 4wt% to 15wt% of a pore-forming component.

[0057] The composition may include 0.1% to 5% of an initiator based on the dry weight of the composition, preferably 0.5 wt% to 4 wt% of an initiator, more preferably 0.75 wt% to 3.5 wt% of an initiator, and most preferably 1 wt% to 3 wt% of an initiator.

[0058] The composition may include up to 5% accelerator by dry weight of the composition, preferably up to 3 wt% accelerator, more preferably up to 2 wt% accelerator, and most preferably up to 1.5 wt% accelerator.

[0059] The composition may include 0.1% to 10% of a dispersant based on the dry weight of the composition, preferably 0.5 wt% to 8 wt% of a dispersant, more preferably 0.75 wt% to 6 wt% of a dispersant, and most preferably 1 wt% to 5 wt% of a dispersant.

[0060] The composition may have a solid content of 45% to 99% by weight of the total composition, such as 50 wt% to 95 wt%, preferably 55 wt% to 90 wt%, and most preferably 60 wt% to 85 wt%.

[0061] This composition can be formed by combining a pre-formed aqueous binder component with a ceramic composition. Suitablely, the aqueous binder component may include polymerizable monomers, crosslinking components, and water.

[0062] Before contacting the liquid ceramic composition with the mold, the composition may be contacted with an initiator and, optionally, a polymerization accelerator.

[0063] The packing member of the present invention can be an inert packing member. Therefore, the inert packing member can be substantially free of catalytic material. Advantageously, the use of the inert packing member according to the invention in the catalyst bed provides improved heat transfer and gas flow turbulence, which facilitates further desired reactions of the reaction medium along the reactor at suitable temperatures.

[0064] The packing member or support of the present invention can be a supported catalyst comprising catalytic material. The catalytic material can be operated to provide catalytic activity in the desired process in which the supported catalyst is applied.

[0065] The catalyst may include one or more metals selected from: transition metals, suitably transition metal oxides; and / or noble metals, suitably alloys thereof. The catalyst may include one or more metals selected from iron, nickel, silver, gold, platinum, ruthenium, vanadium, molybdenum, and cobalt.

[0066] The composition can be mixed appropriately before the addition of the initiator and optional accelerator to form a homogeneous slurry, prior to placement in a mold. Alternatively, the composition can be mixed after the addition of the initiator and optional accelerator to form a homogeneous slurry.

[0067] The mold is preferably a casting mold. The mold can be operated to form a surface structure on the green body.

[0068] The green blanks produced by step (c) can be dried by baking at ≥40°C, such as ≥50°C, ≥55°C, or ≥60°C. Suitablely, the green blanks can be baked for ≥10 hours, such as ≥15 hours, or ≥20 hours, for example, ≥24 hours.

[0069] The green body can be calcined at ≥1000°C, preferably ≥1200°C, more preferably ≥1400°C, and most preferably ≥1500°C. Suitablely, the green body can be fired until substantially all binder and pore-forming components have been removed from the support or supported catalyst.

[0070] The filler component can be impregnated with the catalytic material by immersing it in a solution of the catalytic material. The impregnated filler component can then be dried.

[0071] Advantageously, this invention allows the carrier or supported catalyst preform to be removed from the mold while it is still in a rubber-like form, thus allowing for easier handling. This results in a lower scrap rate compared to other types of casting techniques.

[0072] The guide member of the device of the present invention is operable to suitably guide a mold into an open configuration via a guide member that receives the mold. Suitably, the guide member may include a portion operable to arrange the mold in a closed or at least partially closed position and a portion operable to arrange the mold in a position where mold components are at least partially spaced apart (open position). The mold is operable to move within the guide member from the closed portion of the guide member to the spaced-apart portion of the guide member. Typically, the guide member is operable to arrange the mold in an open position where a portion of the mold components abut and a portion of the mold components are spaced apart, suitably arranged in a position where the dispensing retaining member can be engaged while the mold cavity is open and a reservoir cavity is formed. The guide member is operable to arrange the mold in a position where the dispensing retaining member engages and / or abuts a portion of the mold components while the mold cavity is open and a reservoir cavity is formed, wherein the open mold cavity and / or reservoir cavity is arranged above the abutting portion of the engaged dispensing retaining member and / or mold components. The guide member may also include a drive member operable to move the mold through the guide portion of the guide member.

[0073] The molding equipment may also include a dispensing component operable to dispense the liquid ceramic composition into the mold. Suitably, the dispensing component may be arranged above the guiding portion of the guiding component.

[0074] The packing member can be a catalyst support, preferably a ceramic catalyst support. The packing member can be a supported catalyst.

[0075] The filling component of the present invention can be a castable filling component, such as a gel castable filling component.

[0076] The infill component can have a thickness of ≥0.7cm. 2 / cm 3 Geometric surface area per unit volume (GSA) and lateral crushing strength ≥250 kgf; such as ≥1 cm 2 / cm 3The geometric surface area per unit volume is preferably ≥1.2 cm². 2 / cm 3 The geometric surface area per unit volume, more preferably ≥1.3 cm². 2 / cm 3 The geometric surface area per unit volume is preferably ≥1.4 cm². 2 / cm 3 The geometric surface area per unit volume. The infill component may have a lateral crushing strength of ≥275 kgf, preferably ≥300 kgf, more preferably ≥325 kgf, and most preferably ≥350 kgf.

[0077] The infill component can have a thickness of ≥1.5cm. 2 / cm 3 The geometric surface area per unit volume, and the lateral crushing strength ≥150 kgf; such as ≥1.7 cm 2 / cm 3 The geometric surface area per unit volume is preferably ≥1.9 cm². 2 / cm 3 The geometric surface area per unit volume, more preferably ≥2.1 cm². 2 / cm 3 The optimal geometric surface area per unit volume is ≥2.3 cm². 2 / cm 3 The geometric surface area per unit volume. The infill member may have a lateral crushing strength of ≥170 kgf, preferably ≥185 kgf, more preferably ≥200 kgf, and most preferably ≥215 kgf.

[0078] Infill components can have a diameter of ≥3cm 2 / cm 3 The geometric surface area per unit volume and the lateral crushing strength ≥60 kgf, such as ≥3.3 cm. 2 / cm 3 The geometric surface area per unit volume is preferably ≥3.6 cm². 2 / cm 3 The geometric surface area per unit volume, more preferably ≥3.9 cm². 2 / cm 3 The preferred size is ≥4.2cm. 2 / cm 3 The geometric surface area per unit volume. The filling member may have a lateral crushing strength of ≥70 kgf, preferably ≥80 kgf, more preferably ≥90 kgf, and most preferably ≥100 kgf.

[0079] The geometric surface area per unit volume in this paper is calculated by measuring the external dimensions of the infill component (including all macroscopic and surface structural features) and calculating the surface area. The calculated surface area is then divided by the calculated volume of the infill component. These calculations can be performed quickly and accurately using suitable 3D modeling software.

[0080] The lateral crushing strength described in this paper is expressed in kgf. This is the maximum load recorded at the failure point of the sample when it is crushed between two parallel, flat, hardened steel plates with a minimum diameter of 80 mm. One plate is fixed to a load cell and recording device, while the other plate is attached to an impact device (ram) moving at a controlled rate of 5 mm / min. Preliminary tests are conducted to determine the weakest dimension of the infill member. Then, lateral crushing tests are performed in the direction of the weakest point.

[0081] The filling component may have a porosity of ≥6%, preferably ≥15%, more preferably ≥20%, and most preferably ≥25%. The filling component may have a porosity of 6% to 50%, preferably 15% to 40%, more preferably 20% to 35%, and most preferably 25% to 30%. Suitably, the carrier may have a porosity of ≥15%, more preferably ≥20%, and most preferably ≥25%. The carrier may have a porosity of 15% to 50%, more preferably 20% to 40%, and most preferably 25% to 35%.

[0082] The porosity in this paper was measured by mercury intrusion porosimetry, using ASTM D4284-12(2017)e1, a standard test method for determining the pore volume distribution of catalysts and catalyst supports by mercury intrusion porosimetry.

[0083] The filler member may have a macrostructure and a surface structure located on the outer surface of the macrostructure. Typically, the surface structure of the filler member is formed during the molding step of the filler member (i.e., the step of forming the green blank of the filler member), appropriately by texturing in the mold cavity. Therefore, preferably, the surface structure is not post-processed after molding the green blank of the filler member.

[0084] Macroscopic structures can take the form of multi-lobed (e.g., trilobed, tetralobed, or pentlobed), ring-shaped, spherical, cubic, cuboid, cylindrical, or cog-shaped.

[0085] The macrostructure of the insert includes multiple radially outwardly extending castellations. When the castellations are excluded, the macrostructure of the insert may have a transverse cross-section including approximately circular, triangular, square, or rectangular shapes. At least some, and preferably all, of the castellations may taper gradually along their depth and / or width. Preferably, each castellation tapers gradually in the same direction as the other castellations of the insert, and suitably, the widest and deepest points of the castellations may face the same end of the castellation.

[0086] The macrostructure may have a recessed upper and / or lower surface, suitably with at least 30% of the upper and / or lower surface recessed, such as at least 40% or at least 50%. It should be noted that, according to the invention, the holes extending through the macrostructure are not recesses in the upper and / or lower surfaces.

[0087] Advantageously, it has been found that the interlocking macrostructure with a gradually tapering crenellated structure and / or a concave upper or lower surface provides improved fill density and reduced interlocking.

[0088] The spherical macrostructure may include at least one linear groove, such as at least two, at least three, or at least four linear grooves, on the outer surface of the macrostructure. Preferably, the spherical macrostructure includes at least two parallel linear grooves, such as at least three or at least four parallel linear grooves. Preferably, the transverse cross-section of these grooves is generally hemispherical.

[0089] The macrostructure can be a monolithic structure or include one or more holes extending through it. Preferably, the filler member includes at least one hole extending through the macrostructure; more preferably, the macrostructure includes at least three holes. The macrostructure can be a honeycomb structure. The holes in the macrostructure can be straight-cut or faceted.

[0090] The infill member may include multiple surface structures, suitably including multiple repeating surface structures. Preferably, the infill member includes at least 5 surface structures (suitably including repeating surface structure portions), more preferably at least 10 surface structures, such as at least 15 surface structures, or at least 20 surface structures, and most preferably at least 25 surface structures.

[0091] Surface structure refers to raised and / or recessed portions on the carrier, the height of which is significantly smaller than the width / diameter of the macrostructure of the infill member. Such surface structure can be considered as surface texture on the macrostructure of the infill member. Surface structure can be considered to exclude microscopic surface roughness. For example, the infill member can be a cuboid macrostructure with a width of 32 mm and a length of 50 mm. The outer surface of the infill member may include multiple surface structures in the form of multiple repeating identical discrete mounds, each mound having a height of 2 mm. It should be noted that, according to the present invention, normal features of the macrostructure (such as multiple basalt structures of teeth or multi-leaved lobes) are not considered surface structures.

[0092] The surface structure can take the form of ridges and / or mounds.

[0093] The ridges may be in the form of annular ridges, wherein the annular ridges are not limited to circles. The annular ridges may be generally circular or in the form of regular convex polygons (such as triangles, squares, pentagons, hexagons, heptagons, octagons, nonagons, or decagons). Preferably, the annular ridges are in the form of regular convex polygons, more preferably in the form of pentagons, hexagons, or heptagons, and most preferably in the form of hexagons. The portions of the surface structure extending between the annular ridges may be flat, inclined, and / or curved. For example, the portions of the surface structure extending between the annular ridges may be in the form of inverted pyramids. The surface structure may include a plurality of attached annular ridge structures, suitably interconnected such that at least the ridges of the first annular surface structure form part of the second annular surface structure.

[0094] Surface structures in the form of mounds can be recessed into or protrude outward from the macrostructure. Mounds can be curved, pyramidal, and / or stepped. Stepped mounds can include 2 to 10 steps, such as 3 to 8 steps. Mounds can be interconnected, such that adjacent mounds abut or merge together.

[0095] The desired average height of the surface structure of the filling member can be up to 10 mm, preferably up to 7 mm, more preferably up to 6 mm, and most preferably up to 5 mm.

[0096] The desired average height of the surface structure of the infill component can be at least 0.1 mm, such as at least 0.3 mm, preferably at least 0.5 mm, more preferably at least 0.7 mm, and most preferably at least 0.8 mm. The height of the surface structure described herein was measured using calipers with depth measurement capabilities.

[0097] The maximum size of the infill member can be up to 1000 mm, for example, up to 750 mm or up to 500 mm, preferably up to 400 mm. The width / diameter of the infill member can be up to 500 mm, such as up to 300 mm, or up to 200 mm, preferably up to 150 mm, more preferably up to 100 mm, and most preferably up to 50 mm.

[0098] The desired average height of the surface structure of the infill member can be up to 40% of the width / diameter of the infill member, such as up to 30%, preferably up to 25%, more preferably up to 20%, and most preferably up to 15%.

[0099] The surface structure may extend on at least two surfaces of the infill member (such as at least the side surface and the top and / or bottom surface).

[0100] The surface structure may extend over at least 50% of the side surface of the infill member, such as at least 60%, preferably at least 70%, more preferably at least 80%, and most preferably at least 85%. The surface structure may also extend over at least 50% of the outer surface of the infill member, such as at least 60%, preferably at least 70%, more preferably at least 80%, and most preferably at least 85%. In cases where the surface structure comprises a repeating series of ridges (such as annular ridges), the surface extending between the ridges is included as part of the surface structure for this calculation, even when the surface is substantially flat or the ridges are not interconnected.

[0101] Advantageously, the molds and methods of the present invention allow for the commercially viable production of filler components with improved geometric surface area while still providing excellent strength. Furthermore, the strength and / or porosity of filler components that can be efficiently produced using the present invention can be modified while maintaining the same shape, thereby reducing the need and cost of redesign. In addition, the filler components can provide highly porous carriers while still providing excellent strength. Most advantageously, the filler components provide improved geometric surface area as well as excellent strength and a high level of porosity. The improved geometric surface area of ​​the filler components is particularly advantageous for surface-based applications involving catalytic reactions.

[0102] Filler components can also provide high heat transfer coefficients and other improved properties, such as improved fillability.

[0103] Filler components can also be used to provide excellent filling characteristics with low pressure drop. Filler components can provide improved fill density while maintaining optimal airflow.

[0104] According to a fifth aspect of the present invention, a method for producing a mold according to any one of the first to third aspects of the present invention is provided, the method comprising the following steps:

[0105] a. Optionally, generate a negative digital model of the mold;

[0106] b. Using additive manufacturing to produce a negative mold based on the model, preferably printed using a 3D printer; and

[0107] c. A mold is formed from a female mold.

[0108] According to a sixth aspect of the invention, a method is provided for producing a packed member (such as a support or supported catalyst for a catalyst), the packed member being a packed member according to a fourth aspect of the invention. The method includes the following steps:

[0109] a. Optionally, a digital model of the negative image of the mold according to any one of the first to third aspects of the present invention is generated;

[0110] b. Using additive manufacturing to produce a negative mold based on the model, preferably printed using a 3D printer;

[0111] c. From negative mold to mold;

[0112] d. The molding composition is cast into shape according to the method of the second aspect of the invention to form a filled member or a supported catalyst, wherein the molding composition may be the molding composition defined with respect to the fourth aspect of the invention.

[0113] According to a seventh aspect of the invention, a reactor comprising a catalyst bed is provided, wherein the catalyst bed comprises a packing member according to a fourth aspect of the invention.

[0114] According to an eighth aspect of the invention, a reaction medium comprising a catalyst bed is provided, wherein the catalyst bed comprises a packing member according to a fourth aspect of the invention.

[0115] Appropriately, the reactor or reaction medium may be used to: produce syngas for the synthesis of alcohols such as ammonia, methanol, hydrogen, hydrogen peroxide, and / or by oxidation; for direct reduction of iron (DRI); for the generation of endothermic gases; for catalytic partial oxidation; or for autothermal reforming.

[0116] According to a ninth aspect of the present invention, a filling member according to a fourth aspect of the present invention is provided for use as a catalyst support.

[0117] According to a tenth aspect of the invention, a method for producing syngas (such as ammonia, methanol, hydrogen, hydrogen peroxide, and / or oxidative synthesis of alcohols) is provided, the method comprising using a reactor including a catalyst bed, wherein the catalyst bed includes a packing member according to a fourth aspect of the invention for producing syngas.

[0118] According to an eleventh aspect of the present invention, a method for producing direct reduced iron is provided, the method comprising using a reactor including a catalyst bed, wherein the catalyst bed includes a packing member according to a fourth aspect of the present invention.

[0119] According to a twelfth aspect of the invention, a method for generating an endothermic gas is provided, the method comprising using a reactor including a catalyst bed, wherein the catalyst bed includes a packing member according to a fourth aspect of the invention.

[0120] According to a thirteenth aspect of the invention, a method for catalytic partial oxidation is provided, the method comprising using a reactor including a catalyst bed, wherein the catalyst bed includes a packing member according to a fourth aspect of the invention.

[0121] According to a fourteenth aspect of the invention, a method for autothermal reforming is provided, the method comprising using a reactor including a catalyst bed, wherein the catalyst bed includes a packing member according to a fourth aspect of the invention.

[0122] Any numerical range described herein is intended to include all subranges contained therein. The singular includes the plural, and vice versa. For example, while this document refers to “a” first component and “a” second component, “a” open mold cavity, “a” reservoir forming member, etc., each of these components and one or more of any other components may be used. As used herein, the term “polymer” refers to oligomers as well as homopolymers and copolymers, and the prefix “poly” indicates both or more of them.

[0123] In this article, the term "mold" refers to a container with a hollow portion used to shape a liquid composition when it is hardened into a solid form. A mold can be a casting, a die, or a form.

[0124] In this article, the use of "longitudinal" and "lateral" refers to the storage tank cavity. Thus, longitudinal refers to the axis that extends roughly through the base and opening of the cavity, and lateral refers to the axis that extends roughly perpendicular to the longitudinal axis.

[0125] All the features contained in this article can be combined with any of the above aspects in any combination.

[0126] To better understand the present invention, and to illustrate how embodiments of the invention can be implemented, reference will now be made to the following figures by way of example. Attached Figure Description

[0127] The invention will now be described by way of example only and with reference to the accompanying drawings, in which:

[0128] Figure 1A top perspective view of a first embodiment of a mold according to the present invention is shown.

[0129] Figure 2A and Figure 2B A top view of a second embodiment of the mold according to the present invention is shown.

[0130] Figure 3A A top perspective view of a first embodiment of a molding apparatus is shown, which is formed by a mold according to a second embodiment in an open position.

[0131] Figure 3B It shows Figure 3A A top view of the molding equipment.

[0132] Figure 4A The image shows a mold in a partially closed position. Figure 3A Top perspective view of the molding equipment.

[0133] Figure 4B It shows Figure 4A A top view of the molding equipment.

[0134] Figure 5 A perspective view of the filling member according to the present invention is shown. Specific Implementation

[0135] Figure 1 A mold 10 according to a first embodiment of the present invention is shown. The mold 10 is generally rectangular and is formed by a first mold component 100 and a second mold component 200. The first component 100 and the second component 200 each comprise approximately half the mass of the mold and are each formed of two elastically deformable portions of silicone-based rubber.

[0136] The first mold component 100 is formed from a generally rectangular body 102. The body 102 has a rectangular inner surface and a rectangular outer surface. When the mold components are joined, the inner surface forms the inner surface of the mold, and the outer surface forms the outer surface of the mold. The body 102 also has a rectangular front surface, a rear surface, and two side surfaces.

[0137] The inner surface of the body 102 has a group of twelve discrete, generally hemispherical partial mold cavities 104, each partial mold cavity 104 having a surface texture on its molded surface. The mold cavities are arranged in a group of four rows, with three cavities 104 in each row. The partial cavities 104 are equidistant from adjacent mold cavities to form a laterally centered grid-like arrangement on the inner surface. The first row is located near the edge of the inner surface adjacent to the front surface of the body 102, parallel to but spaced from that edge, and the last row (the fourth row) is located near the edge of the inner surface adjacent to the rear surface, parallel to but spaced from that edge. The first row is closer to its respective edge than the last row is closer to its corresponding edge. Extending along both sides of the grid-like group of partial cavities 104 are protruding side reservoir member tongues 106a and 106b. The side reservoir members tongues 106a and 106b are generally cuboid in shape with convex upper surfaces, and extend longitudinally along the inner surface from the edge adjacent to the front surface, just after the partial cavities 104 in the last row. The side reservoir members tongues 106a and 106b are connected at the bottom end (i.e., the end near the rear surface of the body 102) via the base reservoir member tongue 106c. The base reservoir member 106c has the same height as the side reservoir members 106a and 106b, and extends laterally through the inner surface to connect the reservoir members 106a and 106b. The reservoir members 106a and 106b are integrally connected at each end of the base reservoir member 106c to form a generally U-shaped shell that surrounds the mesh-like grouped partial cavities 104 on both sides and at the bottom (i.e., the end near the rear surface of the body 102). The housing forming portion 104 is located as part of the storage tank cavity 108 therein. The storage tank cavity has a laterally extending opening in the form of an open end, extending between the ends of the side storage tank members that are not connected to the base storage tank member. Thus, the opening is arranged between the edge of the first row of partial cavities and the inner surface adjacent to the front surface of the body 102.

[0138] The mold component 100 also has two sets of three post-dispensing cubic retaining members 110a and 110b, which are integrally formed on both sides with the inner surface and the side reservoir member. Each of the post-dispensing retaining members extends outward from the inner surface and the side reservoir member. The first set of retaining members 110a is arranged along the outer surface of the side reservoir member 106a (relative to the reservoir cavity), and the second set of retaining members 110b is arranged opposite the first set on the outer surface of the side reservoir member 106b. The three retaining members in each set of retaining members 110a and 110b are longitudinally equidistant from the adjacent retaining members of the set, and each retaining member is directly opposite to the corresponding retaining member on the opposite side reservoir member.

[0139] The inner surface of the body 102 is formed by a dispensing tongue member 112, which is spaced apart from the base reservoir member 106c, located below the base reservoir member 106c, and extends parallel to the base reservoir member 106c. It also extends parallel to but spaced apart from the edge of the inner surface adjacent to the rear surface. The dispensing tongue member 112 is a generally cuboid protrusion that extends laterally across the body 102 and is spaced apart from the side edges.

[0140] An elongated recess 114 is located on the inner surface between the openings of the storage cavity 108, near the edge of the inner surface adjacent to the front surface of the body 102, but spaced apart from that edge. The recess 114 is positioned laterally centered on the inner surface between the side edges of the body 102, and spaced apart from the side edges of the body 102. The recess 114 is generally elliptical. The width of the recess 114 is approximately the same as the width of the opening of the storage cavity.

[0141] The first mold component 100 also has three spaced-apart cylindrical reinforcing rods 116, which extend laterally from one side surface through the center mass of the body 102 to another side surface at three different points along the body 102. The rods 116 extend from the side surfaces on both sides, such that each side of the first mold component 100 has three protrusions for use as guide members. The rods 116 are equidistant along the longitudinal length of the body 102.

[0142] The second mold component 200 (not shown) is identical to the first mold component 100, but has inwardly extending concave equivalents of the container component and the retaining component. Therefore, the second mold component 200 has: a corresponding concave reservoir component 206 (not shown), which is a cuboid recess within the body 202 (not shown) adapted to receive the reservoir component of the first mold component 100; and concave retaining components 210 (not shown) and 212 (not shown), which allow convex retaining components 110, 112 to be fitted therein so that they are engaged and to keep the first mold component 100 and the second mold components 100, 200 aligned. When the first mold cavity 100 and the second mold cavity 200 are engaged together, portions of the cavities 104, 204 form a closed, enlarged, generally spherical mold cavity 304 (not shown).

[0143] In use, the mold 10 is arranged in the open position, with the first mold component 100 and the second mold component 200 partially spaced apart, such that the dispensing holding members 112, 212 cooperate to keep the first mold component 100 and the second mold component 200 aligned, and such that the reservoir members 106, 206 (not shown) are fully engaged to form a reservoir cavity in which the base reservoir member forms the base of the cavity, and all mold cavities are open. In this configuration, the front surfaces of the mold components are spaced apart, while the rear surfaces of the mold components are not spaced apart.

[0144] In this initial configuration, the initial reservoir cavity 108 may be filled with a liquid ceramic composition. This is accomplished by allowing the liquid composition to fall from above the spaced-apart front surface of the mold component into the opening of the reservoir cavity 108. The received liquid composition will be held in the cavity 108 and will also enter and fill the mold cavities 104, 204 located within the initial reservoir cavity.

[0145] Then, the mold 10 can be moved to a partially closed position by progressively engaging the side reservoir members 106, 206 upwards from the base reservoir member toward the opening of the reservoir cavity. This action closes the initial reservoir cavity, which closes some of the now-filled mold cavities, but by further engaging the side reservoir members, the reservoir cavities move further upwards along the front surface of the mold components toward the mold 10. The repositioned reservoir cavity carries any remaining composition not occupied by the initially filled mold cavities. This has the effect of transferring a portion of the liquid ceramic composition higher above the grouped cavity members, thereby allowing the composition to move from the repositioned reservoir cavity 108 into a previously empty, open mold cavity that now falls into the repositioned reservoir cavity 108.

[0146] Then, the mold components 100 and 200 can be moved to a closed position, in which the storage tank components 106 and 206 and the dispensing retainer are fully engaged, thereby closing the storage tank cavity and also closing all mold cavities, so that the liquid ceramic composition is held within the closed mold cavity 304. Any excess composition is collected in the recess 114.

[0147] The composition is held within the mold cavity 304 until a green body is formed; optionally, the green body is heated.

[0148] Then, the green blank can be demolded and calcined to produce the filling component.

[0149] Figure 2A and Figure 2B A second embodiment of the mold 20 according to the present invention is shown. The mold 20 is generally rectangular and has a first mold component 300 and a second mold component 400, as shown. Figure 2A and2B As shown in the diagram. The first mold component 300 and the second mold component 400 are structurally substantially the same as the first mold component 100 and the second mold component 200 of the first embodiment. Unless otherwise stated below, the mold 20 has all the features described in the first embodiment.

[0150] The first mold component 300 and the second mold component 400 each include a greater number of partial cavities 305 and 405. There are eleven rows of linearly contiguous and parallel partial cavities 305 and 405, with 15 cavities in each row.

[0151] Side reservoir member tongues 306a and 306b are located on the first mold member 300 and extend longitudinally along the inner surface from just after the last row of partial cavities 305 to the edge of the inner surface adjacent to the front surface of the body 302. Thus, the side reservoir member tongues 306a and 306b, and the base reservoir member tongue 306c, surround the elongated recess 314 and partial cavity 305 located on the inner surface of the body 302. Side reservoir members 406a and 406b are positioned on the second mold member 400 in the same manner.

[0152] Compared to the first embodiment, the number of cubical retaining members 310a and 310b integrally formed on both sides with the inner surface and side storage tank members 306a and 306b after dispensing is increased to seven on each side. There are also seven corresponding recessed retaining members 410a and 410b on the second mold member 400. Eight evenly spaced reinforcing rods 316 extend laterally through the central mass of each mold member in the same manner as in the first embodiment.

[0153] Figures 3 and 4 illustrate a first embodiment of the molding apparatus 30 according to the present invention. The molding apparatus 30 is formed by a mold 20 according to the second embodiment described above and two guide members 450. The guide members 450 are fixed in a vertical direction. Each guide member 450 has two cuboid-shaped grooves 452 that extend longitudinally downward along the guide member at a slightly oblique angle, such that the distance between the two grooves 452 is smaller at the bottom of the guide member 450 than at the top of the guide member 450. The grooves of each guide member are arranged to face and directly oppose the corresponding groove of the other guide member.

[0154] The reinforcing rods 316 and 416 can be fitted into the grooves 452 on the corresponding sides of the mold components to allow the mold 20 to travel along the grooves and be held vertically, such that the front surfaces of the mold components 300 and 400 face upwards and the rear surfaces face downwards.

[0155] In use, by causing rods 316 and 416 to enter groove 452 at the bottom of the guide member and moving the mold upward along the guide member 450 until the front surfaces of mold parts 300 and 400 approach the top of the guide member 450 ( Figure 3A This allows the mold 20 to be positioned in the open position. As the mold components 300 and 400 move upward along the guide member 450, they are spaced apart at their upper ends due to the outward inclination of the groove 452, providing an open position in which an initial reservoir cavity is formed in the space between the mold components. In this position, the dispensing retaining members 312, 412 cooperatively engage at the lower end of the mold to keep the first mold component 300 and the second mold component 400 aligned and to allow the formation of a large reservoir cavity in which the base reservoir member forms the bottom of the cavity and all mold cavities are open.

[0156] In the open position, the initial reservoir 308 can receive the liquid ceramic molding composition by allowing the liquid composition to fall from the dispensing member arranged above the spaced-above front surface of the mold component into the opening 454 of the reservoir cavity 308. The received liquid composition is held in the initial reservoir cavity 308 and fills any mold cavity 305, 405 within the initial reservoir cavity.

[0157] Then, as Figure 4A and Figure 4B As shown, the mold 20 can be moved to a partially closed position by progressively engaging the inner surfaces of the side reservoir members 306, 406 and the mold components upward toward the opening of the reservoir cavity by moving the mold downward along the guide members along the groove. In the partially closed position, the side reservoir members and the inner surfaces of the mold engage further to move the reservoir cavity upward along the mold 20 toward the front surface of the mold component. This action closes the initial reservoir cavity, thereby also closing the filled mold cavity disposed within the initial reservoir cavity. The repositioned reservoir cavity carries any remaining composition not occupied by the initially filled mold cavity. This has the effect of transferring a portion of the liquid ceramic composition higher along the grouped cavity members, thereby allowing the composition to move from the repositioned reservoir cavity 308 to a previously empty, open mold cavity that now belongs to the repositioned reservoir cavity 308. The repositioned reservoir cavity can also receive additional composition from the dispensing member. In the partially closed position, the base of the reservoir cavity is ultimately formed by bringing the inner surface of the mold component into contact with it.

[0158] Then, the mold components 300 and 400 can be moved to the closed position, in which the storage tank components 306 and 406 and the dispensing retaining component 310 are fully engaged, thereby closing the storage tank cavity 308 and also closing all mold cavities to retain the liquid ceramic composition within the closed mold cavity. Any excess composition is collected in the recesses 314 and 414.

[0159] For example, a supported catalyst is produced using molding equipment 30 and a molding composition formed by mixing the components provided below using the method described below.

[0160] Alumina powder, a pore-forming agent, and a dispersant are mixed to form a powder mixture. An aqueous monomer solution containing chain-forming monomers, chain-linking monomers, and water is added to the powder mixture to form an aqueous slurry. Then, a catalyst and an initiator are added to the aqueous slurry. The amounts of each component in the resulting slurry are as follows:

[0161]

[0162] Then, with mold 20 in the open position, the resulting aqueous slurry is poured from the mixing member positioned above mold 20 into the storage cavity of mold 20. Then, as more aqueous slurry is added, mold 20 is gradually moved from the open position to a partially closed position. Then, mold 20 is positioned in the closed position. When the slurry gels into multiple solid green bodies within the enlarged, closed mold cavity, the green bodies are demolded. At this point, the green bodies have a rubbery, jelly-like consistency. Then, the green bodies are dried at room temperature for 24 hours. Then, the dried green bodies are fired at 1450°C, at which point the binder and pore-forming agent are burned off, leaving solid, porous filling components.

[0163] Then, the filling component is immersed in a solution containing the catalyst Ni(NO3). 2 The catalyst was dried in an aqueous solution at 500°C. This impregnation process was repeated twice more to produce a supported catalyst.

[0164] The produced supported catalysts possess macroscopic and surface structures, such as Figure 5The supported catalyst 500 is shown in the figure. The supported catalyst 500 has a macroscopic structure in the shape of a cylindrical toothed insert, comprising: a plurality of pores (a total of 5) extending longitudinally through the support; and a plurality of spaced-apart, longitudinally oriented ventral structures (a total of 10) projecting radially outward from the support. The macroscopic structure of the supported catalyst 500 also has a recess 502 located in the upper surface of the support 500. Each ventral structure of the toothed insert gradually tapers along its depth, such that the supported catalyst 500 has a maximum outer width F (38.0 mm) at the base to a minimum outer width E (35.1 mm) at the upper surface of the supported catalyst 500. Each ventral structure further tapers in width from its widest point at the base of the supported catalyst 500 to its narrowest width at the upper surface of the supported catalyst 500.

[0165] The supported catalyst 500 has a surface structure that extends substantially across the entire outer surface of the supported catalyst 500. This surface structure is generally in the form of interconnected hexagonal ridges 502.

[0166] In this way, open vertical infill can be used to manufacture infill components with improved performance in large quantities within the necessary time span, enabling commercially viable production.

[0167] Note all documents and references submitted concurrently with or prior to this specification relating to this application, which are publicly available together with this specification, and the contents of all such documents and references are incorporated herein by reference.

[0168] All features disclosed in this specification (including any appended claims, abstract, and drawings), and / or all steps of any disclosed method or process, may be combined in any combination unless at least some of such features and / or steps in such combination are mutually exclusive.

[0169] Unless otherwise expressly stated, each feature disclosed in this specification (including any appended claims, abstract, and drawings) can be replaced by alternative features for the same, equivalent, or similar purpose. Therefore, unless otherwise expressly stated, each disclosed feature is merely an example of an equivalent or similar feature in a general series.

[0170] This invention is not limited to the details of the foregoing embodiments. The invention extends to any novel feature or any novel combination thereof disclosed in this specification (including any appended claims, abstract, and drawings), or to any novel step or any novel combination thereof of any disclosed method or process.

Claims

1. A mold for manufacturing a filling component from a liquid ceramic composition, the mold comprising a first mold component and a second mold component, wherein, The first mold component and / or the second mold component includes an open mold cavity, and wherein the first mold component and the second mold component are operable to engage to form a closed mold cavity, wherein the mold further includes a reservoir forming member, and wherein the mold further includes a guide member operable to be received by the guide member such that the mold moves from an open position through the guide member to a partially closed position, and then to a closed position; in the open position, the first mold component and the second mold component are at least partially spaced apart such that the reservoir forming member forms a reservoir cavity and the mold cavity is open; in the partially closed position, the position of the reservoir cavity has been moved relative to the mold cavity, and / or the volume of the reservoir cavity has been reduced; in the closed position, the first mold component and the second mold component engage such that the mold cavity is closed, and wherein in the open position, the mold is operable to receive a molding composition by dispensing a composition from a dispensing member arranged above the partially spaced first mold component and the second mold component.

2. The mold according to claim 1, wherein, Both the first mold component and the second mold component include an open mold cavity.

3. The mold according to claim 2, wherein, The mold cavity of the first mold component and the mold cavity of the second mold component are open partial mold cavities, and the first mold component and the second mold component of the mold can be operated to engage such that the partial mold cavity of the first mold component is aligned with the partial mold cavity of the second mold component to form a closed enlarged mold cavity.

4. The mold according to claim 1, wherein, The first mold component and / or the second mold component include a plurality of open mold cavities.

5. The mold according to claim 4, wherein, Each of the first mold component and / or the second mold component includes a plurality of open partial mold cavities.

6. The mold according to claim 1, wherein, The mold cavity includes a texture that can be manipulated to create a surface structure on the filling member.

7. The mold according to claim 1, wherein, The storage tank forming component includes a first storage tank component disposed on a first mold component and a second storage tank component disposed on a second mold component, wherein the first storage tank component and the second storage tank component can be operated to cooperate in joining to form a storage tank cavity.

8. The mold according to claim 7, wherein, The first storage tank component and the second storage tank component include a convex storage tank component and a concave storage tank component.

9. The mold according to claim 1, wherein, The first mold component and / or the second mold component includes a side reservoir member that extends along opposite sides of the mold cavity of the mold component.

10. The mold according to claim 1, wherein, The first mold component and / or the second mold component include a base storage tank component.

11. The mold according to claim 10, wherein, The base storage tank component is a base storage tank component that extends between the side storage tank components.

12. The mold according to claim 1, wherein, The first mold component and / or the second mold component are elastically deformable.

13. The mold according to claim 1, wherein, The material forming the first mold component and / or the second mold component has a shrinkage rate of up to 1%.

14. The mold according to claim 1, wherein, The first mold component and the second mold component include a cooperative retaining member that can be operated to help maintain the alignment of the first mold component and the second mold component.

15. The mold according to claim 1, wherein, The mold components include reinforcing members.

16. A molding apparatus for use in producing filled components from a liquid ceramic composition, said molding apparatus comprising: The mold according to any one of claims 1 to 15; And a guide component, which can be operated to position the mold in the open position.

17. The molding apparatus according to claim 16, wherein, The guide member can be operated to position the mold in an open position where a portion of the first mold component and a portion of the second mold component abuts and a portion of the first mold component and a portion of the second mold component are spaced apart.

18. The molding apparatus according to claim 17, wherein, In the open position, the mold can be operated to receive a portion of the molding composition from a feeding member disposed above the mold.

19. A method for producing a filling component for use in a filled bed, comprising the following steps: a. A mold comprising a first mold component and a second mold component is arranged in an open position, wherein the first mold component and / or the second mold component comprises an open mold cavity, and wherein the mold further comprises a reservoir forming member, wherein in the open position, the first mold component and the second mold component are at least partially spaced apart such that the reservoir forming member forms a reservoir cavity and the mold cavity is open; the mold is a mold according to any one of claims 1 to 15 or a molding apparatus according to claim 16; b. Fill the reservoir cavity of the mold at least partially with a liquid ceramic composition; c. Move the mold to a partially closed position, such that the position of the storage tank cavity shifts relative to the mold cavity, and / or the volume of the storage tank cavity decreases; and d. Moving the mold to a closed position, wherein the first mold component and the second mold component engage to close the mold cavity, such that a portion of the liquid ceramic composition is retained within the closed mold cavity to form a green body; and e. Demold the green body.

20. The method according to claim 19, wherein, Step b involves filling the reservoir cavity of the mold at least partially with a liquid ceramic composition by dispensing the material from above the mold.

21. The method according to claim 19, wherein, Step c also includes the step of transferring a portion of the liquid ceramic composition from the storage tank cavity into an open mold cavity.

22. The method according to claim 19, wherein, After step d and before step e, there is another step of heating the green blank.

23. The method according to claim 19, wherein, Following step e, there is another step of calcining the green blank to produce the filler component.

24. The method according to claim 19, wherein, The filling component is formed from a casting molding composition or slurry.

25. The method according to claim 24, wherein, The filling component is formed from a gel casting composition.

26. The method of claim 25, wherein, The gel casting composition comprises ceramic materials and organic binder components.

27. The method according to claim 26, wherein, The gel casting composition also includes a pore-forming component.

28. The method according to claim 26, wherein, The organic adhesive component includes a polymerizable component, wherein the adhesive component can be manipulated to polymerize to form a polymer.

29. The method according to claim 26, wherein, The organic adhesive component includes a polymerizable component, wherein the adhesive component can be manipulated to polymerize to form a copolymer.

30. The method according to claim 26, wherein, The organic adhesive components include polymerizable monomers and crosslinking components.

31. The method according to claim 30, wherein, The polymerizable monomers include one or more types of olefinic unsaturated monomers.

32. The method according to claim 30, wherein, The polymerizable monomers include vinyl monomers.

33. The method according to claim 30, wherein, The polymerizable monomer includes one or more acrylic monomers or derivatives of acrylic monomers.

34. The method according to claim 30, wherein, The polymerizable monomer is selected from one or more of methacrylamide, N-(hydroxymethyl)acrylamide, hydroxyethylacrylamide and / or N-vinyl-2-pyrrolidone.

35. The method according to claim 31, wherein, The olefinic unsaturated monomers include one or more acrylamide monomers.

36. The method according to claim 35, wherein, The acrylamide monomer is selected from one or more of methacrylamide, N-(hydroxymethyl)acrylamide and hydroxyethylacrylamide.

37. The method of claim 30, wherein, The polymerizable monomer includes methacrylamide.

38. The method according to claim 30, wherein, The crosslinking component is selected from one or more of diene-bonded unsaturated monomers, acrylates, and / or polyethylene glycol-substituted acrylic monomers.

39. The method according to claim 38, wherein, The diene-bonded unsaturated monomer is a diacrylate monomer or a derivative of a diacrylate monomer.

40. The method according to claim 39, wherein, The diacrylic acid monomer is a diacrylamide monomer.

41. The method according to claim 26, wherein, The ceramic material includes one or more of the following materials: alumina, aluminum silicate, magnesium aluminate, calcium aluminate, zirconium oxide, silicon dioxide, titanate, and magnesium oxide.

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