Moulds for making filled components

Abstract

A mold for manufacturing a filling 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 is elastically deformable, and wherein the first part and / or the second part comprises a plurality of open mold cavities, wherein the first part and the second part are operable to engage to form a closed mold cavity, and wherein the mold is operable to move from an open position to a partially closed position by reducing deformation of the mold parts, and then to a closed position by further reducing deformation of the mold parts; in the open position, the first part and the second part are partially spaced apart by deformation of the mold parts, and in the open position, the mold cavities are open; in the partially closed position, some of the mold cavities are closed; in the closed position, the first part and the second part engage so that the mold cavities are closed.

Description

Technical Field

[0001] The present invention relates to a mold for manufacturing a packing member for a packed bed, in particular to a support for a catalyst and a supported catalyst. More specifically, the present invention relates to a mold for manufacturing a ceramic catalyst support and a supported catalyst for processes such as steam reforming and the production of direct reduced iron. Background Art

[0002] Metal catalysts used in industrial processes such as steam reforming and direct reduced iron production are more active if they are 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 a process is that only a small amount of the more expensive catalytic metal is dispersed on a large amount of abundant, inexpensive support material, thereby greatly reducing the cost of the catalytic material required on a commercial scale.

[0003] In many of these processes, the reactions requiring the catalyst are very fast and limited to the pellet surface. Therefore, the reaction will depend on the geometric surface area of ​​the supported catalyst. In addition, supported catalysts with low internal surface area (BET) and such a small internal pore volume are generally less active in such processes. The strength of the support is also important because breakage during loading, handling and discharge of the supported catalyst will reduce activity and increase delays and costs. For example, in the Midrex process for direct reduced iron (DRI), the catalyst is subjected to high levels of mechanical handling and thermal cycling, as is the case with steam reforming catalysts. In addition, the supported catalyst should provide good heat transfer characteristics while maintaining a low pressure drop.

[0004] Supports for catalysts in such industrial processes are usually prepared by extruding, pelletizing or granulating ceramic powders and then calcining the green bodies.

[0005] However, it has been found that such approaches can only provide limited support geometries and physical properties. For example, such supports can achieve high strength, but only at the expense of small geometric surface area and poor porosity.

[0006] Therefore, there is a need for improved supports for catalysts having a better combination of desirable properties that can be produced economically.It is therefore an object of various aspects of the present invention to address one or more of the above or other problems. Summary of the invention

[0007] According to a first aspect of the present invention, there is provided a mould for manufacturing a filling member from a liquid ceramic composition, the mould comprising a first part and a second part, wherein the first mould part and / or the second mould part is elastically deformable, and wherein the first part and / or the second part comprises a plurality of open mould cavities, wherein the first part and the second part are operable to engage to form a closed mould cavity, and wherein the mould is operable to move from an open position to a partially closed position by reducing deformation of the mould parts, and then to a closed position by further reducing deformation of the mould parts; in the open position, the first part and the second part are partially spaced apart by deformation of the mould parts, and in the open position, the mould cavities are open; in the partially closed position, some of the mould cavities are closed; and in the closed position, the first part and the second part engage so that the mould cavities are closed.

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

[0009] a. arranging a mold comprising a first component and a second component in an open position, wherein the first component and / or the second component are elastically deformable and wherein the first component and / or the second component comprises a plurality of open mold cavities, in which the first component and / or the second component are partially spaced apart by deforming the mold components such that the mold cavities are open;

[0010] b. contacting the mold member with a liquid ceramic composition, appropriately contacting the abutting portion of the first and second members of the mold;

[0011] c. moving the mold to a partially closed position by reducing deformation of the mold members so that some of the mold cavities are closed and a portion of the liquid ceramic composition is retained in the closed mold cavities;

[0012] d. moving the mold to a closed position by further reducing the deformation of the mold parts, so that the first part and the second part are engaged to close other mold cavities and to retain another portion of the liquid ceramic composition in other closed mold cavities to produce a green body; and

[0013] e. Optionally, heating the green body;

[0014] f. demolding the green body; and

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

[0016] According to a third aspect of the present invention, there is provided a moulding apparatus for use in producing a filling member from a liquid ceramic composition, suitably a moulding apparatus for use in a method according to the second aspect of the present invention, the moulding apparatus comprising: a mould according to the first aspect of the present invention; and a guide member operable to arrange the mould in an open position.

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

[0018] The first part and the second part may each comprise a plurality of open mould cavities. Suitably, the first part mould cavity and the second part mould cavity may be open partial mould cavities, and the first part and the second part of the mould are operable to engage such that the partial mould cavity of the first part is aligned with the partial mould cavity of the second part to form a closed enlarged mould cavity. As used herein, an "open" mould cavity may mean that a filling member or green body or a portion thereof is operable to be removed from the mould cavity via the same aperture through which the liquid ceramic composition was introduced into the mould cavity. As used herein, a "closed" mould cavity may mean that the liquid ceramic composition is retained within the mould cavity such that it cannot leave the mould cavity.

[0019] The mould cavity may comprise a texture operable to produce a surface structure on the fill member. Suitably, a surface of the mould cavity operable to contact the liquid ceramic composition during moulding may comprise a texture.

[0020] The mould cavity may comprise a pin operable to form a hole in the filling member, such as a hole extending through the filling member. Suitably, the mould cavity may comprise at least two pins, such as at least three or at least four pins. The pin may be arranged on the bottom surface of the mould cavity and extend upwardly towards the opening of the mould cavity. The pin may be arranged substantially centrally on the bottom surface of the mould cavity. The pin may be cylindrical.

[0021] Suitably, the first mould part and / or the deformable second mould part may be formed from a polymer material such as silicone.The silicone may be formed from a two-part silicone composition comprising a silicone resin and a curing agent or catalyst.

[0022] The Shore hardness of the material forming the first mold part and / or the second mold part can 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 part and / or the second mold part can be up to 40, such as up to 35, or up to 32, such as up to 30. The Shore hardness of the material forming the first mold part and / or the second mold part can be 5 to 40, such as 10 to 35, or 15 to 32, such as 20 to 30. Advantageously, it has been found that materials with Shore hardness within the above ranges provide a mold according to the present invention that is flexible to allow effective molding while maintaining sufficient shape and rigidity. As described herein, Shore hardness is measured using ASTM D2240 Type A.

[0023] The shrinkage of the material forming the first mould part and / or the second mould part 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 within the above ranges provide a mould with improved alignment between mould parts. As described herein, shrinkage may refer to the amount of dimensional change, suitably the amount of dimensional change within a period of 1 week, such as a period of 1 month or a period of 3 months.

[0024] The mold may also include a reservoir forming member. In the open position, the first component and the second component may be spaced apart so that the reservoir member forms a reservoir cavity. In the partially closed position, the position of the reservoir cavity may have been moved relative to the mold cavity, and / or the volume of the reservoir cavity may have been reduced.

[0025] The reservoir member may be 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 substantially inoperable to hold a portion of the composition or to form a molded product.

[0026] The reservoir member may include a first reservoir member arranged on the first mold part and a second reservoir member arranged on the second mold part, wherein the first reservoir member and the second reservoir member are operable to cooperatively engage to form a reservoir cavity. Suitably, the first reservoir member and the second reservoir member may be a convex reservoir member and a concave reservoir member, so that the convex reservoir member is operable to be received in the concave reservoir member to form a reservoir cavity. The convex reservoir member may be in the form of a tongue and the concave reservoir member may be in the form of a groove. Suitably, the convex reservoir member and the concave reservoir member can be operated to form a tight fit when engaged. "Tight fit" herein refers to a fit that can be operated to prevent the liquid ceramic composition from passing through the engaged reservoir members.

[0027] The first mold part and / or the second mold part may include a reservoir member, suitably the reservoir member is a tongue or a groove, the reservoir member extends along the opposite side of the mold cavity of the mold part, and suitably the reservoir member extends longitudinally. Suitably, the first mold part and the second mold part may both include a mold cavity, and the first reservoir member includes a tongue extending along the opposite side of the mold cavity of the mold part, and the second reservoir member includes a groove extending along the opposite side of the mold cavity of the mold part. The reservoir member of the mold part may also include a base reservoir member extending between the side reservoir members. The base reservoir member may extend transversely along the mold part. The base member may be arranged below the mold cavity of the mold part. Suitably, the first reservoir member may include a base tongue extending between opposite side tongues, and / or the second reservoir member may include a base groove extending between opposite side grooves. Such a reservoir member configuration may be in the form of a U-shape, wherein the side reservoir members extend longitudinally along the mold part, and the base reservoir member extends transversely along the mold part between the side reservoir members. The base reservoir member may provide the bottom inner surface or base of the reservoir cavity in use. The side reservoir members may provide the side surfaces of the reservoir cavity in use. The surface of the mold part extending between the side reservoir members may also contain the mold cavity, which may provide the front surface and the rear surface of the reservoir cavity. Typically, the reservoir cavity includes a mouth. The mouth may extend between the ends of the side reservoir members that are not connected to the base reservoir member. Suitably, the mouth of the reservoir cavity may extend laterally across the mold parts, typically substantially parallel to the base storage member.

[0028] Suitably, the first mould part and / or the second mould part may comprise a plurality of mould cavities in a group.The side reservoir members may be arranged to extend along opposite sides of the group of mould cavities.The base member may be arranged to extend below the group of mould cavities.

[0029] The reservoir members of the mould parts may be arranged on the same surface as the mould cavity.The reservoir members of the mould parts may be arranged such that engagement of the reservoir members is operable to align the partial mould cavities on the mould parts to form an enlarged mould cavity in a closed position.

[0030] Therefore, when the mold is in the open position, the reservoir member can be operated to engage to form a reservoir cavity, which can be operated to receive a liquid ceramic composition through the mouth of the reservoir cavity and then keep the liquid ceramic composition in the reservoir cavity. Suitably, when the mold is in the open position, the mold cavity can be arranged in the initial reservoir cavity. When the mold is in the open position, the mold cavity can also be arranged outside the initial reservoir cavity. As the mold moves from the open position to the partially closed position and then to the closed position, the reservoir member of the mold part can be operated to further engage so that the reservoir cavity moves along the grouped mold cavity 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. The movement can be continued until the reservoir member is fully engaged so that the mold cavity is appropriately closed by the engagement between the mold parts above the mold cavity. Typically, the reservoir cavity has a smaller volume than the combined volume of the mold cavity of the mold.

[0031] The mold part may include a retaining member operable to assist in maintaining the alignment of the mold part. The mold part may include a retaining member operable to assist in maintaining the alignment of the mold part during dosing of the liquid ceramic composition into the mold. The dosing retaining member may be spaced apart from the mold cavity and / or the reservoir cavity, for example not providing an inner surface of the reservoir cavity. Typically, the dosing retaining member is not directly attached to the reservoir member. The dosing retaining member may include a cooperating member arranged on the first mold part and the second mold part. Suitably, the cooperating dosing retaining members may be convex and concave, so that the convex retaining member can be received into the concave retaining member to assist in the alignment of the mold part. The convex retaining member may be a tongue and the concave alignment member may be a groove. The retaining member of the mold part may be arranged longitudinally below the mold cavity, suitably below the base of the reservoir cavity. The retaining member may extend laterally along the mold part, substantially parallel to the base of the reservoir cavity or the base reservoir member. Advantageously, the use of the dosing retaining member allows a larger initial reservoir cavity to be formed while maintaining good alignment of the mold parts.

[0032] The mold parts may include post-dosing retention members that are operable to assist in maintaining the alignment of the mold cavities after the liquid ceramic composition is dosed. The post-dosing retention members may be arranged outside the reservoir cavity, for example, such as not providing an inner surface of the reservoir cavity. The post-dosing retention members may include cooperating members arranged on the first mold part and the second mold part. Suitably, the cooperating post-dosing retention members may be convex and concave, so that the convex retention member can be received into the concave retention member to assist in maintaining the alignment of the mold parts. The convex retention member may be a tongue and the concave alignment member may be a groove. The post-dosing retention member may be arranged laterally adjacent to the group of mold cavities. The retention member may extend laterally along the mold part. The post-dosing retention member may include a group of multiple retention members, arranged on each side of the group of mold cavities, suitably laterally adjacent to the group of mold cavities. The groups of retention members may each include at least two retention members, such as at least three retention members, spaced longitudinally along the mold part. Advantageously, the use of a post-dose retention member allows for improved retention of alignment between the mold parts after the composition has been dosed.

[0033] The mold part may include a recessed portion arranged above the mold cavity, suitably above the mouth of the grouped mold cavity and / or reservoir cavity. Typically, the recessed portion is elongated and may extend substantially parallel to the base of the reservoir cavity or the base reservoir member. When the mold part reaches the closed position, the recessed portion may operate to receive any excess composition contained in the reservoir cavity.

[0034] The mould part may comprise guide members. Suitably, the guide members may extend outwardly from the mould part. The mould part may comprise guide members arranged on each of two opposing surfaces of the mould part, suitably arranged on two opposing side surfaces of the mould part. The mould part may comprise at least three guide members, such as at least 4, at least 5 or at least 6 guide members on each of two opposing surfaces of the mould part. The surface of the mould part may comprise guide members arranged towards opposing ends of the surface and intermediate guide members arranged between the end guide members.

[0035] The mould part may comprise a reinforcing member, which may suitably be more rigid than the main body of the mould part. The reinforcing member may be arranged at least partially within the main body of the mould part. The reinforcing member may extend substantially from one end of the main body of the mould part to the other end, such as to the opposite end. The reinforcing member may protrude from the mould part to provide a guide member. Suitably, the reinforcing member may protrude on opposite sides of the mould part to provide a guide member on the opposite sides of the mould part. Thus, the guide member may be provided by the protruding reinforcing member.

[0036] The filling member may be formed from a cast molding composition or slip, such as a clay or non-clay castable composition, a liquid cement or a gel casting composition. Thus, the liquid ceramic composition may be a gel casting composition, which may suitably include a ceramic material, an organic binder component and an optional pore forming component.

[0037] The organic binder component is operable to be substantially removed from the filling member after molding of the filling member, preferably by heat treatment, more preferably during calcination of the filling member.

[0038] The organic binder component may comprise a polymerisable component, suitably the polymerisable component may comprise a polymerisable monomer and a cross-linking ingredient, wherein the binder component is operable to polymerise to form a (co)polymer.

[0039] The polymerizable monomer may include: one or more types of ethylenically unsaturated monomers, such as acrylic acid monomers or derivatives of acrylic acid monomers, 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 includes monomers selected from one or more of methacrylamide (MAM), N-(hydroxymethyl)acrylamide (hMAM) and hydroxyethylacrylamide (hEAM). Most preferably, the polymerizable monomer includes MAM.

[0040] The cross-linking component may be selected from one or more of a diethylenically unsaturated monomer, an acrylate, and / or a polyethylene glycol-substituted acrylic acid monomer, the diethylenically unsaturated monomer being such as a diacrylic acid monomer or a derivative of a diacrylic acid monomer, the derivative of the diacrylic acid monomer being such as a diacrylamide monomer. The cross-linking component may be selected from one or more of poly(ethylene glycol) dimethacrylate (PEGDMA), N,N'-methylenebis(acrylamide) (BIS), ammonium acrylate, and PEG methylethyl acrylate (PEGMEM), preferably one or more of poly(ethylene glycol) dimethacrylate (PEGDMA) and N,N'-methylenebis(acrylamide) (BIS).

[0041] The organic binder component can be formed from 40wt% to 95wt% of a polymerizable monomer and 60wt% to 5wt% of a cross-linking component, such as 50wt% to 90wt% of a polymerizable monomer and 50wt% to 10wt% of a cross-linking component, or 55wt% to 85wt% of a polymerizable monomer and 45wt% to 15wt% of a cross-linking component, or 60wt% to 80wt% of a polymerizable monomer and 40wt% to 20wt% of a cross-linking component, such as 65wt% to 75wt% of a polymerizable monomer and 35wt% to 25wt% of a cross-linking component.

[0042] The composition may also include a polymerization accelerator that can be operated to accelerate the polymerization of the adhesive component. The polymerization accelerator may be any suitable accelerator. For example, the accelerator may be tetramethylethylenediamine (TEMED).

[0043] The composition may also include an initiator operable to initiate polymerization of the adhesive component. The initiator may be any suitable initiator. The initiator may be a free radical initiator. For example, the initiator may be ammonium persulfate and / or potassium persulfate.

[0044] The pore forming material is operable to be removed from the filling member after moulding of the filling member, preferably by heat treatment, more preferably during calcination of the filling member.The pore forming material may be selected from one or more of microbeads, starch, seeds and / or cellulose.

[0045] The pore-forming material may have the following particle size distribution, wherein D 10 The D of the pore-forming material 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. 50 The D of the pore-forming material may be 50 μm to 200 μm, preferably 75 μm to 175 μm, more preferably 90 μm to 160 μm, and most preferably 100 μm to 150 μm. 90 The thickness may be 120 μm to 300 μm, preferably 150 μm to 270 μm, more preferably 170 μm to 250 μm, and most preferably 185 μm to 235 μm.

[0046] The ceramic material may be a refractory ceramic material. The ceramic material may include alumina, aluminum silicate, magnesium aluminate, calcium aluminate, zirconium oxide, silicon dioxide, titanate, carbon and / or magnesium oxide.

[0047] The ceramic material may have a particle size distribution as follows, where D 10 The D of the pore-forming material 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. 50The diameter of the pore-forming material may be 0.5 μm to 30 μm, preferably 1 μm to 25 μm, more preferably 1.5 μm to 20 μm, and most preferably 2 μm to 15 μm. 90 The diameter may be 10 μm to 100 μm, preferably 15 μm to 80 μm, more preferably 20 μm to 70 μm, and most preferably 25 μm to 60 μm.

[0048] The ceramic material may be a ceramic powder. The ceramic powder may be ball milled or spray dried. Advantageously, it has been found that ball milled or spray dried ceramic powders provide properties that are easier to cast.

[0049] The composition or packing member may include a promoter that can operate to increase the reactivity of the primary reaction, and / or reduce undesirable side reactions. The promoter may be selected from one or more of the oxides of lanthanum, copper, magnesium, manganese, potassium, calcium, zirconium, barium, cerium, sodium, lithium, molybdenum, yttrium, cobalt and chromium.

[0050] The composition may further comprise a carrier, such as an aqueous carrier. Suitably, the composition may be an aqueous ceramic slurry.

[0051] The composition may include other additives. For example, the composition may include a dispersant, such as a polymer salt, for example a salt of polyacrylic acid, preferably an ammonium salt of polyacrylic acid. Suitable dispersants may be selected from one or more of Ecodis P90, Narlex LD42 and Dispex A40.

[0052] The composition may comprise 0.1% to 10% polymerizable monomer, preferably 0.5wt% to 8wt% polymerizable monomer, more preferably 1wt% to 6wt% polymerizable monomer, for example 1.5wt% to 5wt% polymerizable monomer, most preferably 2wt% to 4wt% polymerizable monomer, based on the dry weight of the composition.

[0053] The composition may comprise 0.1% to 10% cross-linking ingredient, preferably 0.5wt% to 8wt% cross-linking ingredient, more preferably 0.75wt% to 6wt% cross-linking ingredient, such as 1wt% to 5wt% cross-linking ingredient, most preferably 1wt% to 4wt% cross-linking ingredient, based on the dry weight of the composition.

[0054] The composition may comprise 50% to 95% ceramic material, preferably 50% to 90% ceramic material, more preferably 55% to 85% ceramic material, most preferably 60% to 80% ceramic material, based on the dry weight of the composition. The filling member may comprise at least 75% ceramic material, preferably at least 85% ceramic material, more preferably at least 90% ceramic material, such as at least 95% ceramic material, most preferably at least 97% ceramic material, based on the dry weight of the composition.

[0055] The composition may comprise >0% to 40% pore-forming ingredient, preferably 0.5wt% to 30wt% pore-forming ingredient, more preferably 2wt% to 25wt% pore-forming ingredient, such as 3wt% to 20wt% pore-forming ingredient, most preferably 4wt% to 15wt% pore-forming ingredient, based on the dry weight of the composition.

[0056] The composition may comprise from 0.1% to 5% initiator, preferably from 0.5wt% to 4wt% initiator, more preferably from 0.75wt% to 3.5wt% initiator, most preferably from 1wt% to 3wt% initiator, based on the dry weight of the composition.

[0057] The composition may comprise up to 5% accelerator, preferably up to 3 wt% accelerator, more preferably up to 2 wt% accelerator, most preferably up to 1.5 wt% accelerator by dry weight of the composition.

[0058] The composition may comprise from 0.1% to 10% dispersant, preferably from 0.5wt% to 8wt% dispersant, more preferably from 0.75wt% to 6wt% dispersant, most preferably from 1wt% to 5wt% dispersant by dry weight of the composition.

[0059] The composition may have a solids content of 45% to 99% by weight of the total composition, such as 50% to 95% by weight, preferably 55% to 90% by weight, most preferably 60% to 85% by weight.

[0060] The composition may be formed by combining a preformed aqueous binder component with the ceramic composition. Suitably, the aqueous binder component may include a polymerisable monomer, a crosslinking ingredient and water.

[0061] Prior to contacting the liquid ceramic composition with the mold, the composition may be contacted with an initiator and optionally a polymerization accelerator.

[0062] 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 present invention in the catalyst bed provides improved heat transfer and gas flow turbulence, which helps the reaction medium to further proceed along the reactor at a suitable temperature for the desired reaction.

[0063] The packing member or support of the present invention may be a supported catalyst comprising a catalytic material. The catalytic material may operate to provide catalytic activity in the desired process in which the supported catalyst is applied.

[0064] The catalytic material may comprise a metal selected from one or more of the following: a transition metal, suitably a transition metal oxide; and / or a noble metal, suitably an alloy thereof. The catalytic material may comprise a metal selected from one or more of iron, nickel, silver, gold, platinum, ruthenium, vanadium, molybdenum and cobalt.

[0065] The composition may be mixed to form a homogenous slurry before being arranged in the mould, suitably before the addition of the initiator and optionally the accelerator. The composition may be mixed to form a homogenous slurry after the addition of the initiator and optionally the accelerator.

[0066] The mould is preferably a casting mould.The mould can be operated to form a surface structure on the green body.

[0067] The green body produced by step (c) may be dried by baking the green body at ≥40°C, such as ≥50°C or ≥55°C or ≥60°C. Suitably, the green body may be baked for ≥10 hours, such as ≥15 hours or ≥20 hours, for example ≥24 hours.

[0068] The green body may be calcined at ≥ 1000° C., preferably ≥ 1200° C., more preferably ≥ 1400° C., most preferably ≥ 1500° C. Suitably, the green body may be fired until substantially all of the binder and pore-forming components have been removed from the support or supported catalyst.

[0069] The packing member may be impregnated with the catalytic material by dipping the packing member into a solution of the catalytic material. The impregnated packing member may be dried after impregnation.

[0070] Advantageously, the present invention enables the support or supported catalyst green body to be removed from the mold while it is still in a rubber-like form, allowing for easier handling. This results in lower scrap rates compared to other types of casting techniques.

[0071] The guide member of the apparatus of the present invention can be operated to guide the mold into an open configuration by deforming the mold part, suitably by receiving the guide member of the mold. Suitably, the guide member may include a portion that can be operated to arrange the mold in a closed or at least partially closed position and a portion that can be operated to arrange the mold in a position (open position) where the mold parts are at least partially spaced apart. The mold can be operated to move from the closed portion of the guide member to the spaced apart portion of the guide member in the guide member. Generally, the guide member can be operated to arrange the mold in an open position where a portion of the mold parts abut and a portion of the mold parts are spaced apart, suitably arranged in a position where the batch holding member is engaged while the mold cavity is open and a reservoir cavity is formed. The guide member can be operated to arrange the mold in a position where the batch holding member engages and / or a portion of the mold part abuts while the mold cavity is open and a reservoir cavity is formed, wherein the open mold cavity and / or the reservoir cavity are arranged above the abutting portion of the engaged batch holding member and / or the mold part. The guide member may also include a drive member that can be operated to move the mold through the guide portion of the guide member.

[0072] The moulding apparatus may further comprise a dosing member operable to dispense the liquid ceramic composition into the mould. Suitably, the dosing member may be arranged above the guide portion of the guide member.

[0073] The packing member may be a catalyst support, suitably a ceramic catalyst support.The packing member may be a supported catalyst.

[0074] The filling member of the present invention may be a cast filling member, such as a gel cast filling member.

[0075] The filling member may have a diameter of ≥ 0.7 cm 2 / cm 3 Geometric surface area per unit volume (GSA) and side crushing strength of ≥250kgf; such as ≥1cm 2 / cm 3 Geometric surface area per unit volume, preferably ≥ 1.2 cm 2 / cm 3 The geometric surface area per unit volume is preferably ≥ 1.3 cm 2 / cm 3 Geometric surface area per unit volume, preferably ≥ 1.4 cm 2 / cm 3 The filling member may have a side crushing strength of ≥275 kgf, preferably ≥300 kgf, more preferably ≥325 kgf, and most preferably ≥350 kgf.

[0076] The filling member may have a size of ≥1.5 cm 2 / cm 3 Geometric surface area per unit volume, and side crushing strength ≥150kgf; such as ≥1.7cm 2 / cm 3 Geometric surface area per unit volume, preferably ≥ 1.9 cm 2 / cm 3 The geometric surface area per unit volume is preferably ≥ 2.1 cm 2 / cm 3 Geometric surface area per unit volume, preferably ≥ 2.3 cm 2 / cm 3 The filling member may have a side crushing strength of ≥170 kgf, preferably ≥185 kgf, more preferably ≥200 kgf, and most preferably ≥215 kgf.

[0077] The filling member may have a size of ≥3 cm 2 / cm 3 Geometric surface area per unit volume and side crushing strength of ≥60kgf, such as ≥3.3cm 2 / cm 3 Geometric surface area per unit volume, preferably ≥ 3.6 cm 2 / cm 3 The geometric surface area per unit volume is preferably ≥ 3.9 cm 2 / cm 3 , most preferably ≥4.2cm 2 / cm 3 The filling member may have a side crushing strength of ≥70 kgf, preferably ≥80 kgf, more preferably ≥90 kgf, and most preferably ≥100 kgf.

[0078] The geometric surface area per unit volume herein is calculated by measuring the external dimensions of the filling member (including all macrostructures and surface structural features) and calculating the surface area. The calculated surface area is then divided by the calculated volume of the filling member. Suitable 3D modeling software can be used to quickly and accurately perform these calculations.

[0079] The side crushing strength herein is expressed by a value in kgf. This is the maximum load recorded at the failure point of the sample when the sample is squeezed and crushed between two parallel, flat, hardened steel plates with a minimum diameter of 80 mm. One plate is fixed to a load cell and a recording device, and the other is attached to a ram that moves at a controlled rate of 5 mm / minute. Preliminary tests are carried out to determine the weakest dimension of the filling member. Then, the side crushing test is carried out in the weakest direction.

[0080] The filling member may have a porosity of ≥6%, preferably a porosity of ≥15%, more preferably a porosity of ≥20%, and most preferably a porosity of ≥25%. The filling member may have a porosity of 6% to 50%, preferably a porosity of 15% to 40%, more preferably a porosity of 20% to 35%, and most preferably a porosity of 25% to 30%. Suitably, the carrier may have a porosity of ≥15%, more preferably a porosity of ≥20%, and most preferably a porosity of ≥25%. The carrier may have a porosity of 15% to 50%, more preferably a porosity of 20% to 40%, and most preferably a porosity of 25% to 35%.

[0081] The porosity in this article is measured by mercury intrusion porosimetry using ASTM D4284-12(2017)e1, Standard Test Method for Determining Pore Volume Distribution of Catalysts and Catalyst Supports by Mercury Intrusion Porosimetry.

[0082] The filling member may have a macrostructure and a surface structure located on the outer surface of the macrostructure. Typically, the surface structure of the filling member is formed during the molding step of the filling member (i.e., the step of forming the green body of the filling member), suitably by suitable texturing in the mold cavity. Therefore, preferably, the surface structure is not post-processed after molding the green body of the filling member.

[0083] The macrostructures may be in the form of multiple lobes (eg, three, four or five lobes), rings, spheres, cubes, cuboids, cylinders or cogs.

[0084] The cog macrostructure comprises a plurality of castellations extending radially outwardly. When the castellations are excluded, the cog macrostructure may have a transverse cross-section comprising a generally circular, triangular, square or rectangular shape, etc. At least some of the castellations, and preferably all of the castellations may taper along the depth and / or width of the castellations, preferably each castellation tapers in the same direction as the other castellations of the cog, suitably the widest and deepest points of the castellations may be towards the same end of the castellations.

[0085] The macrostructure may have a concave upper and / or lower surface, and suitably at least 30% of the upper and / or lower surface may be concave, such as at least 40% or at least 50%. It should be noted that according to the present invention, the holes extending through the macrostructure are not concave in the upper and / or lower surface.

[0086] Advantageously, it has been found that cog macrostructures having tapered castellations and / or concave upper or lower surfaces provide improved packing density and reduced interlocking.

[0087] The spherical macrostructure may include at least one linear groove on the outer surface of the macrostructure, such as at least two, at least three or at least four linear grooves. Preferably, the spherical macrostructure includes at least two linear parallel grooves, such as at least three or at least four linear parallel grooves. Preferably, the transverse cross-section of these grooves is generally hemispherical.

[0088] The macrostructure may be a monolithic structure or include one or more holes extending through the macrostructure. Preferably, the filling member includes at least one hole extending through the macrostructure, more preferably, the macrostructure includes at least three holes. The macrostructure may be a honeycomb structure. The holes of the macrostructure may be straight cut or faceted.

[0089] The filling member may comprise a plurality of surface structures, suitably comprising a plurality of repeated surface structures. Preferably, the filling member comprises at least 5 surface structures (suitably comprising repeated surface structure parts), more preferably at least 10 surface structures, such as at least 15 surface structures, or at least 20 surface structures, most preferably at least 25 surface structures.

[0090] Surface structure refers to raised and / or recessed portions on a carrier, the height of which is significantly less than the width / diameter of the macrostructure of the filling member. Such surface structure can be considered as a surface texture on the macrostructure of the filling member. It can be considered that the surface structure does not include microscopic surface roughness. For example, the filling member can be a cuboid macrostructure with a width of 32 mm and a length of 50 mm. The outer surface of the filling member may include a plurality of surface structures in the form of a plurality of repeated identical discrete hillocks, each hill having a height of 2 mm. It should be noted that according to the present invention, normal features of the macrostructure (such as a plurality of castellated structures of a cog or a multi-leaf leaf) are not considered as surface structures.

[0091] The surface structures may be in the form of ridges and / or hills.

[0092] The ridge may be in the form of an annular ridge, wherein the annular ridge is not limited to a circle. The annular ridge may be in the form of a roughly circular shape or a regular convex polygon (such as a triangle, square, pentagon, hexagon, heptagon, octagon, nonagon or decagon). Preferably, the annular ridge is in the form of a regular convex polygon, more preferably in the form of a pentagon, hexagon or heptagon, most preferably in the form of a hexagon. The portion of the surface structure extending between the annular ridges may be flat, inclined and / or curved. For example, the portion of the surface structure extending between the annular ridges may be in the form of an inverted pyramid. The surface structure may include a plurality of attached annular ridge structures, appropriately interconnected annular ridge structures, so that at least the ridge of the first annular surface structure forms a part of the second annular surface structure.

[0093] The surface structure in the form of a hillock may be recessed into the macrostructure or protrude outwardly from the macrostructure. The hillock may be curved, pyramidal and / or stepped. The stepped hillock may include 2 to 10 steps, such as 3 to 8 steps. The hillocks may be interconnected so that adjacent hillocks abut or merge together.

[0094] The desired mean average height of the surface structures of the filling member may be at most 10 mm, preferably at most 7 mm, more preferably at most 6 mm, most preferably at most 5 mm.

[0095] The desired average height of the surface structures of the filling member may 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, most preferably at least 0.8 mm. The height of the surface structures herein is measured using a caliper with a depth measurement function.

[0096] The maximum dimension of the filling member can be at most 1000mm, for example at most 750mm or at most 500mm, preferably at most 400mm. The width / diameter of the filling member can be at most 500mm, such as at most 300mm, or at most 200mm, preferably at most 150mm, more preferably at most 100m, most preferably at most 50mm.

[0097] The desired average height of the surface structures of the filling member may be at most 40%, such as at most 30%, preferably at most 25%, more preferably at most 20%, most preferably at most 15% of the width / diameter of the filling member.

[0098] The surface structure may extend over at least two surfaces of the filling member, such as at least a side surface and a top and / or bottom surface.

[0099] The surface structure may extend over at least 50% of the side surface of the filling 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 extend over at least 50% of the outer surface of the filling member, such as at least 60%, preferably at least 70%, more preferably at least 80%, and most preferably at least 85%. 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.

[0100] Advantageously, the molds and methods of the present invention allow for commercially viable production of packing members having improved geometric surface areas while still providing excellent strength. In addition, the strength and / or porosity of packing members that can be efficiently produced using the present invention can be modified while maintaining the same shape, thereby reducing the requirements and costs of redesign. In addition, the packing members can provide a highly porous support while still providing excellent strength. Most advantageously, the packing members can provide improved geometric surface areas as well as excellent strength and high levels of porosity. The improved geometric surface area of ​​the packing members is particularly advantageous for applications where catalytic reactions are surface-based.

[0101] The packing members may also provide high heat transfer coefficients and other improved properties, such as improved packing.

[0102] The packing members may also be used to provide excellent packing characteristics with low pressure drop. The packing members may provide improved packing density while maintaining optimal airflow.

[0103] According to a fifth aspect of the present invention, there is provided a method for producing a mold according to any one of the first to third aspects of the present invention, the method comprising the following steps:

[0104] a. Optionally, generating a negative digital model of the mold;

[0105] b. producing a negative mold based on the model using additive manufacturing, preferably printed with a 3D printer; and

[0106] c. Forming a mold from a negative mold.

[0107] According to a sixth aspect of the present invention, there is provided a method for producing a packing member (such as a carrier or a supported catalyst for a catalyst), which packing member may be a packing member according to the fourth aspect of the present invention. The method comprises the following steps:

[0108] a. Optionally, generating a digital model of a negative image of the mold according to any one of the first to third aspects of the present invention;

[0109] b. Using additive manufacturing to produce a negative mold according to the model, preferably printed with a 3D printer;

[0110] c. From negative mold to mold;

[0111] d. Suitably according to the method of the second aspect of the invention, casting the moulding composition to form a packed member or supported catalyst, suitably casting a moulding composition as defined in relation to the fourth aspect of the invention.

[0112] According to a seventh aspect of the present invention, there is provided a reactor comprising a catalyst bed, wherein the catalyst bed comprises a packing member according to the fourth aspect of the present invention.

[0113] According to an eighth aspect of the present invention, there is provided a reaction medium comprising a catalyst bed, wherein the catalyst bed comprises a packing member according to the fourth aspect of the present invention.

[0114] Suitably, the reactor or reaction medium may be used for: producing synthesis gas, such as ammonia, methanol, hydrogen, hydrogen peroxide and / or oxidative synthesis alcohols; for direct reduced iron (DRI); for generating endothermic gases; for catalytic partial oxidation; or for autothermal reforming.

[0115] According to a ninth aspect of the present invention, there is provided a use of the filling member according to the fourth aspect of the present invention as a catalyst carrier.

[0116] According to the tenth aspect of the present invention, a method for producing synthesis gas (such as ammonia, methanol, hydrogen, hydrogen peroxide and / or oxidative synthetic alcohols) is provided, the method comprising using a reactor comprising a catalyst bed, wherein the catalyst bed comprises a filling member according to the fourth aspect of the present invention to produce synthesis gas.

[0117] According to an eleventh aspect of the present invention, there is provided a method for producing direct reduced iron, the method comprising using a reactor comprising a catalyst bed, wherein the catalyst bed comprises a packing member according to the fourth aspect of the present invention.

[0118] According to a twelfth aspect of the present invention, there is provided a method for producing an endothermic gas, the method comprising using a reactor comprising a catalyst bed, wherein the catalyst bed comprises a packing member according to the fourth aspect of the present invention.

[0119] According to a thirteenth aspect of the present invention, there is provided a method for catalytic partial oxidation, the method comprising using a reactor comprising a catalyst bed, wherein the catalyst bed comprises a packing member according to the fourth aspect of the present invention.

[0120] According to a fourteenth aspect of the present invention, there is provided a method for autothermal reforming, the method comprising using a reactor comprising a catalyst bed, wherein the catalyst bed comprises a packing member according to the fourth aspect of the present invention.

[0121] Any numerical range described herein is intended to include all subranges contained therein. The singular encompasses the plural and vice versa. For example, although "a" first component and "a" second component, "a" open mold cavity, "a" reservoir forming member, etc. are mentioned herein, 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" refers to two or more.

[0122] The use of "mold" herein is used to refer to a container having a hollow portion that is used to give shape to a liquid composition when it hardens into a solid form. The mold can be a casting, a die or a former.

[0123] "Longitudinal" and "transverse" are used herein with respect to the reservoir cavity such that longitudinal refers to an axis extending generally through the base and mouth of the cavity, and "transverse" refers to an axis extending generally perpendicular to the longitudinal axis.

[0124] All features contained herein may be combined with any of the above aspects in any combination.

[0125] For a better understanding of the invention, and to show how embodiments of the invention may be carried into effect, reference will now be made, by way of example, to the following drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0126] The present invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:

[0127] Figure 1 A top perspective view is shown of a first embodiment of a mould according to the invention.

[0128] Figure 2A and Figure 2B A top view of a second embodiment of a mould according to the invention is shown.

[0129] Figure 3A A top perspective view of a first embodiment of a molding apparatus formed by a mold according to a second embodiment in an open position is shown.

[0130] Figure 3B Shows Figure 3A A top view of the molding equipment.

[0131] Figure 4A Shown is a mold having a partially closed position Figure 3A A top perspective view of a molding apparatus.

[0132] Figure 4B Shows Figure 4A A top view of the molding equipment.

[0133] Figure 5 A filling member according to the invention is shown. Specific embodiments

[0134] Figure 1 A mold 10 according to a first embodiment of the present invention is shown. The mold 10 is generally cuboid and is formed of a first mold part 100 and a second mold part 200. The first part 100 and the second part 200 each contain approximately half the mass of the mold 10 and are each formed of two parts of elastically deformable silicone-based rubber.

[0135] The first mold part 100 is formed by a generally rectangular parallelepiped body 102. The body 102 has a rectangular inner surface and a rectangular outer surface. When the mold parts 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.

[0136] The inner surface of the body 102 has twelve discrete, generally hemispherical partial mold cavities 104 in groups, which contain surface textures on the molding surface of the cavities. The mold cavities are arranged in a group of four rows, with three cavities 104 in each row. The partial cavities 104 are spaced equidistantly from adjacent mold cavities to form a grid-like grouped arrangement that is laterally centered 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 the edge but spaced from the edge, and the last row (the fourth row) is located near the edge of the inner surface adjacent to the rear surface, parallel to the edge but spaced from the edge. The first row is closer to the above-mentioned edge than the last row is to the corresponding above-mentioned edge. Extending along both sides of the partial cavities 104 in the grid, the side reservoir member tongues 106a and 106b extend out. The side reservoir member tongues 106a, 106b are in the shape of a generally rectangular parallelepiped with a convex upper surface, and they extend longitudinally along the inner surface from the edge adjacent to the front surface to just after the last row of partial cavities 104. The side reservoir member tongues 106a, 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 the base reservoir member 106c extends transversely through the inner surface to connect the reservoir members 106a and 106b. The reservoir members 106a, 106b are integrally connected at each end of the base reservoir member 106c to form a generally U-shaped housing that surrounds the grid-like grouped partial cavities 104 at both sides and the bottom (i.e., the end near the rear surface of the body 102). The housing forms part of a reservoir cavity 108 in which the partial cavities 104 are located. The reservoir cavity has a transversely extending mouth in the form of an open end extending between the ends of the side reservoir members that are not connected to the base reservoir member. Thus, the mouth is arranged between the first row of partial cavities and the edge of the inner surface adjacent to the front surface of the body 102.

[0137] The mold part 100 also has two groups of three cubic holding members 110a, 110b after batching, which are integrally formed on both sides with the inner surface and the side tank member. Each of the holding members after batching extends outward from the inner surface and the side tank member. The first group of holding members 110a is arranged along the outer side surface (relative to the tank cavity) of the side tank member 106a, and the second group of holding members 110b is arranged to be opposite to the first group on the outer side surface of the side tank member 106b. The three holding members in each group of holding members 110a and 110b are longitudinally equidistantly spaced from the adjacent holding members of the group along the inner surface downward, and each holding member is directly opposite to the corresponding holding member on the opposite side tank member.

[0138] The inner surface of the body 102 is formed by an ingredient holding tongue member 112, which is spaced from, located below and extending parallel to the base reservoir member 106c, and proximal to the edge of the inner surface adjacent to the rear surface, extending parallel to but spaced from the edge. The ingredient holding member 112 is a generally rectangular parallelepiped protrusion and extends laterally across the body 102 and is spaced from the side edges.

[0139] The elongated recessed portion 114 is located on the inner surface between the mouth of the reservoir cavity 108 and proximal to the edge of the inner surface adjacent to the front surface of the body 102, but spaced apart from the edge. The recessed portion 114 is relatively laterally centrally located on the inner surface between the side edges of the body 102 and spaced apart from the side edges of the body 102. The recessed portion 114 is generally oval in shape. The recessed portion 114 is approximately the same width as the mouth of the reservoir cavity.

[0140] The first mold part 100 also has three spaced apart cylindrical reinforcing rods 116 extending transversely from one side surface through the center mass of the body 102 to the other side surface at three different points along the body 102. The rods 116 extend from the side surfaces on both sides so that there are three protrusions on either side of the first mold part 100 to serve as guide members. The rods 116 are equally spaced apart along the longitudinal length of the body 102.

[0141] The second mold part 200 (not shown) is identical to the first mold part 100, but has inwardly extending female equivalents of the container members and retaining members. Thus, the second mold part 200 has: a corresponding female reservoir member 206 (not shown), which is a rectangular parallelepiped recess in the body 202 (not shown) adapted to receive the reservoir member of the first mold part 100; and female retaining members 210 (not shown) and 212 (not shown) which allow the male retaining members 110, 112 to fit therein so that they are engaged and the first mold part 100 and the second mold parts 100, 200 are maintained in alignment. When the first mold cavity 100 and the second mold cavity 200 are engaged together, the partial cavities 104, 204 form a closed, enlarged, generally spherical mold cavity 304 (not shown).

[0142] In use, the mold 10 is arranged in an open position with the first mold part 100 and the second mold part 200 spaced apart by deformation of the mold parts so that the ingredient retaining members 112, 212 cooperatively engage to maintain alignment of the first mold part 100 and the second mold part 200. In this configuration, the front surfaces of the mold parts are spaced apart and the rear surfaces of the mold parts are not spaced apart.

[0143] In this initial configuration, the mold member abutment points can receive liquid ceramic composition. This is accomplished by injecting the liquid composition from above the spaced-apart front surfaces of the mold members into the mouth of the reservoir cavity 108. The received liquid composition will be retained in the cavity 108 and will also enter and fill the mold cavity 104, 204 located within the initial reservoir cavity.

[0144] The mold 10 can then be moved to a partially closed position by progressively reducing the deformation of the mold members so that the mold members abut higher up the mold. This action further engages the side reservoir members 106, 206 from the base reservoir member upward toward the mouth of the reservoir cavity. This causes the initial reservoir cavity to close, closing some of the now filled mold cavities, but by further engaging the mold members, the reservoir cavities move further up the mold 10 toward the front surfaces of the mold members. Any remaining composition not occupied by the initially filled mold cavity is transferred higher up the grouped cavity members into the previously empty, open mold cavity.

[0145] The mold parts 100, 200 can then be moved to a closed position by further reducing the deformation of the mold parts so that the mold parts are fully engaged, thereby closing the reservoir cavity and also closing all mold cavities so that the liquid ceramic composition is retained within the closed mold cavity 304. Any excess composition is collected in the recess 114.

[0146] The composition is held within the mold cavity 304 until a green body is produced; optionally, the green body is heated.

[0147] The green body may then be demoulded and fired to produce a filled component.

[0148] Figure 2A and Figure 2B 2 shows a second embodiment of a mold 20 according to the present invention. The mold 20 is generally in the shape of a rectangular parallelepiped and has a first mold part 300 and a second mold part 400. Figure 2A and 2B The first mold part 300 and the second mold part 400 are structurally similar to the first mold part 100 and the second mold part 200 of the first embodiment, and in particular, both are elastically deformable. Unless otherwise specified below, the mold 20 has all the features described in the first embodiment.

[0149] The first mould part 300 and the second mould part 400 comprise a greater number of partial cavities 305 and 405, respectively. There are eleven linear co-bounded and parallel rows of partial cavities 305, 405, with 15 cavities per row.

[0150] Side reservoir member tongues 306a and 306b are located on the first mold part 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 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 recesses 314 and partial cavities 305 located on the inner surface of the body 302. The side reservoir members 406a and 406b are positioned on the second mold part 400 in the same manner.

[0151] Compared to the first embodiment, the number of post-dosing cubic-shaped retaining members 310a, 310b integrally formed on both sides with the inner surface and side reservoir members 306a, 306b is increased to seven on each side. There are also seven corresponding female retaining members 410a, 410b on the second mold part 400. There are eight evenly spaced reinforcing rods 316 extending transversely through the central mass of each mold part in the same manner as the first embodiment.

[0152] 3 and 4 show a first embodiment of a molding apparatus according to the present invention. The molding apparatus is formed by a mold according to the above-mentioned second embodiment and two guide members 450. The guide members 450 are fixed in a vertical direction. Each guide member 450 has two rectangular parallelepiped-shaped grooves 452, which extend longitudinally downward along the guide member at a slight angle, so 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 groove of each guide member is arranged to face and directly oppose the corresponding groove of the other guide member.

[0153] Reinforcement rods 316, 416 may fit into grooves 452 located on respective sides of the mold members to allow mold 20 to travel along the grooves and be held vertically with the front surfaces of mold members 300 and 400 facing upward and the rear surfaces facing downward.

[0154] In use, the mold is moved upward along the guide member 450 by allowing the rods 316 and 416 to enter the groove 452 at the bottom of the guide member until the front surface of the mold parts 300 and 400 is close to the top of the guide member 450 ( Figure 3A ) to arrange the mold 20 in the open position. As the mold parts 300 and 400 move upward along the guide member 450, the mold parts 300 and 400 are deformed so that the mold parts are spaced apart at the upper end to provide the open position. In this position, the ingredient retaining members 312, 412 cooperatively engage at the lower end of the mold to keep the first mold part 300 and the second mold part 400 aligned.

[0155] In the open position, the mold can receive a liquid ceramic molding composition by causing the liquid composition to fall from a dosing member disposed above the spaced-apart front surface of the mold member into the mouth 454 of the reservoir cavity 308. The received liquid composition is retained in the initial reservoir cavity 308 and fills any mold cavity 305, 405 within the initial reservoir cavity.

[0156] Then, if Figure 4A and Figure 4B As shown in , the mold 20 can be moved to a partially closed position by causing the mold to move downward along the guide member along the groove to reduce the deformation of the mold part to further engage the side reservoir members 306, 406 and the inner surface of the mold part from the base reservoir member upward toward the mouth of the reservoir cavity in a progressive manner. In the partially closed position, the side reservoir members and the inner surface of the mold are further engaged to move the reservoir cavity further upward along the mold 20 toward the front surface of the mold part. This action closes the initial reservoir cavity, thereby also closing the filled mold cavity arranged in the initial reservoir cavity. The repositioned reservoir cavity carries any remaining composition that is not occupied by the initial 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 the previously empty open mold cavity, which now belongs to the repositioned reservoir cavity 308. The repositioned reservoir cavity can also receive additional composition from the batching member. In the partially closed position, as deformation of the mold parts is reduced, the base of the reservoir cavity is ultimately formed by abutting the inner surfaces of the mold parts.

[0157] Then, the mold parts 300, 400 can be moved to the closed position by further reducing the deformation of the mold parts until the mold parts are fully engaged, thereby closing the reservoir cavity 308 and also closing all mold cavities to retain the liquid ceramic composition in the closed mold cavities. Any excess composition is collected in the recessed portion 314, 414.

[0158] By way of example, a supported catalyst is produced using the molding apparatus 30 and a molding composition formed by mixing the components provided below using the method described below.

[0159] Alumina powder, pore former and dispersant are mixed to form a powder mixture. An aqueous monomer solution comprising a chain forming monomer, a chain connecting monomer 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 amount of each component in the resulting slurry is:

[0160]

[0161] The resulting aqueous slurry is then poured from a batching member disposed above the mold 20 into the reservoir cavity of the mold 20 while the mold 20 is in the open position. The mold 20 is then gradually moved from the open position to the partially closed position as further aqueous slurry is added. The mold 20 is then arranged in a closed position. When the slurry gels into a plurality of solid green bodies within the closed enlarged mold cavity, the green bodies are then demolded. At this point, the green bodies have a rubbery, jelly-like consistency. The green bodies are then placed at room temperature to dry for 24 hours. The dried green bodies are then fired to 1450°C, at which point the binder and pore formers are burned off, leaving a solid, porous filling member.

[0162] Then, the filling member is immersed in a catalytic material Ni(NO3) 2 The catalyst was then impregnated with water and dried at 500° C. The catalytic material impregnation step was repeated twice to produce a supported catalyst.

[0163] The produced supported catalyst has macrostructure and surface structure, e.g. Figure 5 . The supported catalyst 500 has a macrostructure in the shape of a cylindrical cog having: a plurality of holes (5 in total) extending through the longitudinal length of the carrier; and a plurality of spaced-apart, longitudinally oriented castellations (10 in total) protruding radially outward from the carrier. The macrostructure of the supported catalyst 500 also has a depression 502 located in the upper surface of the carrier 500. Each castellation of the cog tapers along the depth so 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 castellation further tapers in width from the widest point at the base of the supported catalyst 500 to the narrowest width at the upper surface of the supported catalyst 500.

[0164] The supported catalyst 500 has a surface structure extending substantially over the entire outer surface of the supported catalyst 500. The surface structure is generally in the form of interconnected hexagonal ridges 502.

[0165] In this way, packing members with improved properties may be manufactured in the large quantities required using open vertical filling within the necessary time span to achieve commercially viable production.

[0166] Attention is paid to all documents and documents filed concurrently with or before the specification in connection with the present application, which are open to the public with the present specification, and the contents of all such documents and documents are incorporated herein by reference.

[0167] All features disclosed in this specification (including any accompanying 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 the combination are mutually exclusive.

[0168] Unless otherwise expressly stated, each feature disclosed in this specification (including any attached claims, abstracts and drawings) may be replaced by alternative features for the same, equivalent or similar purposes. Therefore, unless otherwise expressly stated, each feature disclosed is only an example of a general series of equivalent or similar features.

[0169] The present invention is not limited to the details of the foregoing embodiments. The present invention extends to any novel one or any novel combination of the features disclosed in this specification (including any attached claims, abstract and drawings), or to any novel one or any novel combination of the steps of any disclosed method or process.

Claims

1. A mold for manufacturing a filling member from a liquid ceramic composition, the mold comprising a first mold part and a second mold part and a reinforcing rod, the reinforcing rod being able to fit into a groove located on the respective sides of the first mold part and the second mold part, wherein the groove extends longitudinally downward along a guide member diagonally so that the distance between the two grooves is smaller at the bottom of the guide member than at the top of the guide member, wherein The first mold part and / or the second mold part are elastically deformable, and wherein the first mold part and / or the second mold part include a plurality of open mold cavities, wherein the first mold part and the second mold part are operable to engage to form a closed mold cavity, and wherein the mold is operable to move from an open position to a partially closed position by a guide member by reducing deformation of the mold parts, and then to a closed position by further reducing deformation of the mold parts by a guide member; in the open position, the first mold part and the second mold part partially separate deformation of the mold parts by a guide member, and in the open position, the mold cavities are open; in the partially closed position, some of the mold cavities are closed; in the closed position, the first mold part and the second mold part engage so that the mold cavity is closed, and wherein in the open position, the mold is operable to receive a molding composition by dispensing the composition from a dosing member arranged above the partially spaced-apart first mold part and the second mold part.

2. The mold according to claim 1, wherein: The first mold part and the second mold part each include a plurality of open mold cavities.

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

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

5. The mold according to claim 1, wherein: The deformable mold member is formed from a polymer material.

6. The mold according to claim 5, wherein: The deformable mold member is formed from silicone.

7. The mold according to claim 5, wherein: The deformable mold member is formed from a two-part silicone composition including a silicone resin and a curing agent or catalyst.

8. The mold according to claim 1, wherein: The Shore hardness of the material forming the first mold member and / or the second mold member is 5 or more.

9. The mold according to claim 8, wherein: The material forming the first mold member and / or the second mold member may have a Shore hardness of 15 or more.

10. The mold according to claim 1, wherein The material forming the first mold member and / or the second mold member may have a Shore hardness of 40 or less.

11. The mold according to claim 10, wherein: The material forming the first mold member and / or the second mold member may have a Shore hardness of 32 or less.

12. The mold according to claim 1, wherein: The mold further includes a reservoir forming member, wherein in the open position the first mold part and the second mold part are operable to be spaced apart such that the reservoir forming member forms a reservoir cavity.

13. The mold according to claim 12, wherein: In the partially closed position, the position of the reservoir cavity may be manipulated to have been moved relative to the mould cavity, and / or the volume of the reservoir cavity may have been reduced.

14. The mold according to claim 1, wherein The material forming the first mould part and / or the second mould part may have a shrinkage of at most 1%.

15. The mold according to claim 1, wherein The mold components include cooperating retaining members operable to assist in maintaining alignment of the mold components.

16. The mold according to claim 1, wherein The mold component includes a reinforcement member.

17. A moulding apparatus for use in producing a filling member from a liquid ceramic composition, the moulding apparatus comprising: The mold according to any one of claims 1 to 16; and a guide member operable to arrange the mold in an open position.

18. The molding apparatus according to claim 17, wherein: The guide member is operable to place the mold in an open position in which a portion of the mold members abut and a portion of the mold members are spaced apart.

19. The molding apparatus according to claim 17, wherein: In the open position, the mold is operable to receive a portion of the molding composition from a batching member disposed above the mold.

20. A method for producing a packing member for use in a packed bed, comprising the steps of: a. arranging a mould comprising a first mould part and a second mould part in an open position, wherein the first mould part and / or the second mould part are elastically deformable and wherein the first mould part and / or the second mould part comprises a plurality of open mould cavities, in which open position the first mould part and / or the second mould part are partially spaced apart by deforming the mould parts such that the mould cavities are open; the mould being a mould according to any one of claims 1 to 16 or a moulding apparatus according to any one of claims 17 to 19; b. contacting the mold member with a liquid ceramic composition, suitably contacting the abutting portion of the mold where the first mold member and the second mold member abut; c. moving the mold to a partially closed position by reducing deformation of the mold parts so that some of the mold cavities are closed and a portion of the liquid ceramic composition is retained in the closed mold cavities; d. moving the mold to a closed position by further reducing the deformation of the mold members, so that the first mold member and the second mold member are engaged to close other mold cavities and to retain another portion of the liquid ceramic composition in other closed mold cavities to produce a green body; and e. demolding the green body.

21. The method according to claim 20, wherein: Step b also includes the step of batching from above the mold.

22. The method according to claim 20, wherein: Step d further comprises the step of heating the green body.

23. The method according to claim 20, wherein: The method further comprises the step of calcining the green body to produce a filling component.

24. The method according to claim 20, wherein: The filling member is formed from a cast moulding composition or slip.

25. The method according to claim 24, wherein: The filling member is formed from a gel cast composition.

26. The method according to claim 25, wherein: The gel casting composition includes ceramic material and organic binder components.

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

28. The method according to claim 26, wherein: The organic binder component includes a polymerizable component, wherein the binder component is operable to polymerize to form a polymer.

29. The method according to claim 26, wherein: The organic binder component includes a polymerizable component, wherein the binder component is operable to polymerize to form a copolymer.

30. The method according to claim 28 or 29, wherein: The polymerizable component includes a polymerizable monomer and a cross-linking component.

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

32. The method of claim 30, wherein: The polymerizable monomer is selected from acrylic acid monomers or derivatives of acrylic acid monomers and / or vinyl monomers.

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

34. The method of claim 30, wherein: The cross-linking component is selected from one or more of a diene-unsaturated monomer, an acrylate and / or a polyethylene glycol-substituted acrylic acid monomer.

35. The method of claim 30, wherein: The cross-linking component is a diacrylic acid monomer or a derivative of a diacrylic acid monomer.

36. The method of claim 30, wherein: The cross-linking component is a diacrylamide monomer.

37. The method of claim 26, wherein: The ceramic material includes alumina, aluminum silicate, magnesium aluminate, calcium aluminate, zirconium oxide, silicon dioxide, titanate, and / or magnesium oxide.

38. A packing member for use in a packed bed, the packing member being obtained by molding a liquid ceramic composition in a mold according to any one of claims 1 to 16, by molding a liquid ceramic composition in a molding apparatus according to any one of claims 17 to 19, or by a method according to any one of claims 20 to 23.

39. A filling member according to claim 38, wherein The filling member is formed from a cast moulding composition or slip.

40. A filling member according to claim 39, wherein The filling member is formed from a gel cast composition.

41. A filling member according to claim 40, wherein The gel casting composition includes ceramic material and organic binder components.

42. A filling member according to claim 41, wherein The gel-cast composition also includes a pore-forming component.

43. A filling member according to claim 41, wherein The organic binder component includes a polymerizable component, wherein the binder component is operable to polymerize to form a polymer.

44. A filling member according to claim 41, wherein The organic binder component includes a polymerizable component, wherein the binder component is operable to polymerize to form a copolymer.

45. A filling member according to claim 43 or 44, wherein The polymerizable component includes a polymerizable monomer and a cross-linking component.

46. ​​A filling member according to claim 45, wherein The polymerizable monomers include: one or more types of ethylenically unsaturated monomers.

47. A filling member according to claim 45, wherein The polymerizable monomer is selected from acrylic acid monomers or derivatives of acrylic acid monomers and / or vinyl monomers.

48. A filling member according to claim 45, wherein The polymerizable monomer is one or more monomers selected from acrylamide, methacrylamide, N-(hydroxymethyl)acrylamide, hydroxyethylacrylamide and / or N-vinyl-2-pyrrolidone.

49. A filling member according to claim 45, wherein The cross-linking component is selected from one or more of a diene-unsaturated monomer, an acrylate and / or a polyethylene glycol-substituted acrylic acid monomer.

50. The filling member of claim 45, wherein The cross-linking component is a diacrylic acid monomer or a derivative of a diacrylic acid monomer.

51. The filling member of claim 45, wherein The cross-linking component is a diacrylamide monomer.

52. A filling member according to claim 41, wherein The ceramic material includes alumina, aluminum silicate, magnesium aluminate, calcium aluminate, zirconium oxide, silicon dioxide, titanate, and / or magnesium oxide.

53. A reactor comprising a catalyst bed, wherein: The catalyst bed comprises a packing member according to any one of claims 38 to 52.

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